Composite article assembly systems and methods

ABSTRACT

A composite article assembly arrangement includes mechanized assembly station tooling for supporting certain composite article assembly methodologies with a view toward a preferred lid assembly application. First assembly station tooling includes a stationary main base plate, opposed intermediate compactor plates, and opposed outer plates, which compactor plates and outer plates are movable relative to the stationary main base plate. One or more continuous webs bearing thermoformed first and second workpieces are directed through the mechanized assembly station tooling, which operates to both separate the first and second workpieces from the web(s) as directed therethrough and assemble the first and second workpieces in one clapping movement of the compactor plates and outer plates relative to the main base plate. Alternative assembly station tooling operates to direct first composite elements into assembled relation with stationary second composite elements for forming basic composites to which successive composite elements are similarly added.

PRIOR HISTORY

This application is a divisional and continuation-in-part patentapplication claiming the benefit of pending U.S. Patent Application No.16/661,765 filed in the U.S. Patent and Trademark Office (USPTO) on 23Oct. 2019, which application claims the benefit of expired U.S.Provisional Patent Application No. 62/749,627 filed in the USPTO on 23Oct. 2018 the specifications and drawings of which are herebyincorporated by reference thereto.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to certain production linesystems and associated methods for forming composite articles as appliedto exemplary two-piece lid assemblies. More particularly, the presentinvention relates to production line assembly tooling stations havingall-in-one functionality whereby, either in a single bi-directionalclapping movement or a unidirectional movement, first and secondworkpieces are assembled into a composite article and removed from apreferred web conveyor.

Brief Description of the Prior Art

U.S. Pat. No. 7,353,582 ('582 Patent), issued to MacKenzie et al.,discloses a Method for Assembling a Closure Tab to a Lid. The '582Patent describes a method and apparatus for assembling a firstthermoformed workpiece, such as a tab closure, to a second thermoformedworkpiece, such as a lid. The invention described by the '582 Patentrelates to an automated manufacturing line for making a compositethermoformed article from first and second thermoformed workpieces byautomatically assembling the first thermoformed workpiece to the secondthermoformed workpiece. The automated manufacturing line comprises athermoforming station for thermoforming the first and secondthermoformed workpieces in a plastic sheet, a trim station for trimmingat least the first thermoformed workpiece from the plastic sheet; and anassembly tooling station for assembling the first thermoformed workpieceonto the second thermoformed workpiece to form the composite article.

U.S. Pat. No. 7,523,534 ('534 Patent), issued to MacKenzie et al.,discloses a Method for Assembling a Closure Tab to a Lid. Similar to the'582 Patent, the '534 Patent describes certain methods for assembling afirst thermoformed workpiece, such as a closure tab, to a secondthermoformed workpiece, such as a lid. The assembly tooling station ofthe '534 Patent further describes a carrier mechanism that moves betweena first position, where it picks the first thermoformed workpiece, and asecond position, where it assembles the first thermoformed workpiece tothe second thermoformed workpiece. A suction device can be added to thecarrier to pick the first thermoformed workpiece as it is trimmed fromthe sheet and hold the first thermoformed workpiece as it is carried tothe second thermoformed workpiece. Additionally, a force reliever can beadded to the carrier to control the amount of force applied by thecarrier to the first and second thermoformed workpieces as they areassembled.

United States Patent Application Publication No. 2009/0283526, authoredby Pierce et al., discloses a Molded, Recyclable, Compostable CelluloseFiber Lid Assembly for a Container. The Pierce et al. publicationdescribes a lid assembly, comprising a dome portion, a rim-receivingportion, and a compression ring are configured to attach to a containerand provide a seal between the lid assembly and the container. The lidassembly is made of a reusable, recyclable, and compostable material,such as molded paper, pulp, natural cellulose fibers cellulose fiber,tapioca, wood, agricultural recycled crop materials, plastics (PLA),clay, metals, petro-plastics, silicone, PVC's, and PET styrene.

The prior art perceives a need for a substantially simultaneous,dual-action composite article assembly system and method that operatesto eliminate the structural requirement to carry a second workpiece to afirst workpiece for article assembly. The state of the art teachescomplex systems for workpiece transfer within a three-dimensional space,leading to inefficiency in workpiece-to-workpiece assembly. To overcomethe structural requirement of carrying workpieces to other workpieces,the prior art perceives a need for a single step motion wherebyworkpieces can be removed from thermoformed webs and in the single stepmotion be assembled with one another. The present invention attempts toaddress this perceived need by providing certain composite articleassembly methodologies supported by all-in-one assembly tooling stationsand associated production line technology, as summarized in more detailhereinafter.

SUMMARY OF THE INVENTION

Among the many objectives of this invention is the provision of acomposite article assembly production line or arrangement comprising anall-in-one assembly tooling station for supporting certain compositearticle assembly methodologies as exemplified by two-piece lidassemblies. The all-in-one assembly tooling stations according to thepresent invention essentially comprise a stationary main base plate,opposed intermediate compactor plates, and opposed outer plates, whichcompactor plates and outer plates are movable relative to the stationarymain base plate.

One or more continuous webs bearing thermoformed workpieces, exemplifiedby upper lid bodies and lower lid bodies, are directed through theassembly tooling stations, which stations operate to both separate theworkpieces from the web(s) as directed therethrough and assemble theworkpieces in one clap-like or clapping movement of the compactor platesand outer plates relative to the main base plate. The main base platecomprises an axial alignment chamber or cavity that operates tomechanically or structurally maintain axial alignment of the workpiecesas they are assembled to form the composite article.

The composite article assembly method supported by the all-in-oneassembly tooling stations according to the present invention may be saidto comprise the basic steps of forming workpieces exemplified by upperlid bodies or disks and lower lid bodies or primary lid formations viastate-of-the-art thermoforming station(s). The workpieces are thenplaced or directed into axial alignment with one another along anassembly alignment axis extending through the assembly site orchamber(s) of the main base plate of the all-in-one assembly toolingstation(s).

Once placed into axial alignment with one another, the workpieces aredirected toward one another within the assembly tooling station alongthe assembly alignment axis or alignment axes in the case of multipleassembly chambers formed in the main base plate. When directed towardone another, distance between the respectively aligned workpieces isdecreased to the point when aligned upper workpieces approaches zero,and the first and second workpieces are assembled under the forced anddirected engagement into one another to form composite articlesexemplified by two-piece lid assemblies.

Central to the practice of the present invention are the steps ofdirecting the first and second workpieces toward one another within theassembly tooling station along the assembly alignment axis, andassembling the first and second workpieces along or in parallel relationrelative to the assembly alignment axis within the all-in-one assemblytooling station(s) as performed in a single clap-like or clappingmovement of opposed tooling as exemplified by intermediate compactorplates and outer plates opposite the stationary main base plate withinwhich workpiece assembly occurs.

The present invention is believed centered on the substantiallysimultaneous, dual-action (with sequential momentary delays as may berequired), workpiece-cut and workpiece-to-workpiece assembly stepwhereby the opposed tooling is directed towards one another fordirecting a first workpiece (e.g. an upper lid body or disk) intoengagement with a second workpiece (e.g. a lower lid body or primary lidformation) for forming composite articles. In other words, when thefirst workpiece is cut from the web it is directed (not carried)) intoassembled relation with the second workpiece also being cut from the webduring one clap-like, to-and-fro, or back and forth tooling movementwithin the all-in-one assembly tooling station(s) thereby providing acomposite formed article or two-workpiece assembly.

The step of forming first workpieces and second workpieces via theprimary body-forming or thermoforming stations comprises or includes thestep of forming the such workpieces on at least one continuous web.However, the present invention further contemplates the formation ofsuch workpieces or composite formed articles on at least a pair of, orat least two continuous webs, directing the pair or at least twocontinuous webs via at least two separate primary thermoforming stationsin a web-to-station flow or direction (i.e. into or toward a singularall-in-one assembly tooling station).

The composite article assembly method according to the present inventionfurther comprises the step of removing (e.g. via a select cuttingprocess) a select body formation from the at least one continuous webbefore directing first and second workpieces toward one another withinthe assembly tooling station, which select body formation is selectedfrom the group consisting of the first workpieces and the secondworkpieces. The select cutting process may be selected from the groupconsisting of a die-cutting process or a circular knife-cutting process.

The composite article assembly method may further preferably comprise orinclude the step of forming first and second workpieces on the least onecontinuous web via the at least one thermoforming station such that thefirst and second workpieces are formed in spaced and alternatingrelation to one another. The at least one continuous web may be furtherdirected through a secondary body-forming station as exemplified bypre-punch stations after forming the first and second workpieces via theprimary thermoforming station(s). The secondary body-forming stationsfunction to form secondary formations as exemplified by sip holes, airvents, or other similar secondary apertures in select workpieces asselected from the group consisting of the first and second workpieces.

When the production line is built around a single, continuous web, thecomposite article assembly method may further preferably comprise thestep of directing the spaced and alternating first and second workpiecesthrough a loop mechanism so as to axially align the first and secondworkpieces within the singular assembly tooling station for formingcomposite articles. Bearing in mind that the all-in-one assembly toolingstations all provide a basis for the described methodology, themethodology may further preferably comprise the step of directing thefirst and second workpieces into a stationary plate structurallyenhancing axial alignment of the first and second workpieces during thestep of assembling the first and second workpieces along the assemblyalignment axis.

The present invention may further preferably comprise the step ofdirecting at least two or a series of workpieces into a portion of thestationary plate before directing a first of the series of workpiecesinto assembled relation with a singular second workpiece. In otherwords, a series of workpieces (e.g. disks) may be directed into adisk-guiding shaft of the main base plate before a first of theworkpieces (e.g. disks) is expelled, discharged or otherwise directedfrom the disk-guiding shaft into engagement with an underlying liddepression of a workpiece (e.g. a lower lid body). It will thus beunderstood that the disk-guiding shaft of the stationary plate maytemporarily store at least one workpiece for later discharge as governedby the operator.

The present invention embraces the concept of adjusting tooling featuresin a manner that cooperates with inherent resiliency of materials toprovide for better assembly characteristics. For example, a compactorshaft and compactor head may be finely adjusted so as to resilientlydeform a first workpiece prior to separation from the web and directedtransfer through the disk-guiding shaft into engagement with theunderlying workpiece. Accordingly, the present methodology contemplatesthe step of resiliently deforming a select body formation before thestep of assembling the first and second workpieces along the assemblyalignment axis within the assembly tooling station, which select bodyformation is selected from the group consisting of the first and secondworkpieces. The step of resiliently deforming the select body formationfunctions to adjustably enhance workpiece assembly.

An alternative multi-piece composite article assembly method accordingto the present invention essentially involves the centralized use of aconveyor, preferably in the form of a thermoformable web, provided oroutfitted with a series of multiple, axially alignable compositeelements. The composite elements are formed or provided upon a firstface of the planar web conveyor facing a first direction. The conveyormay preferably be directed through a first loop mechanism such that thefirst face first faces a second direction opposite the first directionwhen exiting the loop mechanism. First and second composite elements arethen axially aligned within the mechanized assembly station toolingalong an assembly alignment axis.

Once the first and second composite elements are axially aligned, thefirst composite element is directed toward the second composite elementwithin the mechanized assembly station tooling along the assemblyalignment axis. The first composite element and the second compositeelement are then assembled along the assembly alignment axis within themechanized assembly station tooling thereby forming a basic composite.The method may further comprise the step of twisting the conveyor at atwist portion downflow from the basic composite assembly site forre-orienting the assembly alignment axis for successive elementalalignment and assembly.

The steps of directing the first composite element toward the secondcomposite element within the mechanized assembly station tooling alongthe assembly alignment axis and assembling the first composite elementwith the second composite element along the assembly alignment axiswithin the mechanized assembly station tooling are preferably performedby unidirectionally moving the first composite element along theassembly alignment axis toward the second composite element as fixed inposition within the tooling.

It is contemplated the conveyor primarily functions as anelement-conveying mechanism. In certain applications, the carrierconveyor may be preferably exemplified as a web type conveyor with themultiple, axially alignable composite elements being thermoformedtherein before entry into the mechanized assembly station tooling thatoperates to form composite articles. Sets of the multiple, axiallyalignable composite elements are preferably positioned upon the firstface of the conveyor in spaced and alternating relation to one another.

The multi-piece composite article assembly methodology may furthercomprise the step(s) of directing successive composite elements intoassembled relation with the basic composite within the mechanizedassembly station tooling along successive assembly alignment axesthereby forming a complex composite. The mechanized assembly stationtooling may preferably alignment cavities formed in alignment plate(s)of the tooling such that composite elements may be directed therethroughor thereinto for enhancing axial alignment of the composite elementswhen assembling the composite elements along the assembly alignment axiswithin the mechanized assembly station tooling.

The present specifications further contemplate certain workpiecestacking methodology or workpiece cutting methodology for providing astacked series of workpieces for ease of packaging. The workpiecestacking or cutting methodology according to the present inventioncontemplates the essential steps of stacking a series of web sheets atopone another into a web sheet stack. Each web sheet may provide at leastone, but preferably a series of workpiece sites. The web sheet stack maythus preferably comprise at least one stack of web-based workpieces.

The web sheet stack may be positioned in (inferior) adjacency to ashaft-receiving plate assembly, which shaft-receiving plate assemblycomprises at least one, but preferably a series of shaft-receivingapertures or bores. The at least one stack of web-based workpieces arepreferably positioned in adjacency to the shaft-receiving aperture(s).At least one tubular shaft, but preferably a plurality of tubular shaftsmay be directed through the web sheet stack via the shaft-receivingaperture(s) thereby separating the web-based workpieces from the seriesof web sheets and forming a stacked series of workpieces within thetubular shaft.

The stacked series of lid formations or workpieces are linearly directedinto the tubular shaft as the tubular shaft is directed through the websheet stack. In this regard, each tubular shaft preferably comprises atubular shaft end, which tubular shaft end is preferably outfitted witha cutting implement or knife. The cutting implement cuts through the websheet stack as the tubular shaft is directed therethrough. The tubularshaft preferably comprises external threads, and the shaft receivingaperture or bore is preferably outfitted with a thread-drivinginterface. The thread-driving interface and external threads arecooperable for converting rotational motion to linearly directed motionthereby directing the tubular shaft linearly through the web sheetstack.

Other secondary objects of the present invention, as well as particularfeatures, elements, and advantages thereof, will be elucidated or becomeapparent from, the following brief descriptions of the drawings and theaccompanying drawing figures.

BRIEF DESCRIPTIONS OF THE DRAWINGS

Other features and objectives of the invention will become more evidentfrom a consideration of the following brief descriptions of patentdrawings.

FIG. 1 is a schematic drawing showing a first introductory productionline arrangement with a schematic side view depiction of a firstall-in-one assembly tooling station forpunching+trimming+assembling+packaging lower lid bodies and upper lidbodies according to the present invention, the first all-in-one assemblytooling station being shown in a first stage of production.

FIG. 2 is a schematic drawing showing the first introductory productionline arrangement with a schematic side view depiction of the firstall-in-one assembly tooling station for trimming and assembling lowerlid bodies and upper lid bodies according to the present invention, thefirst all-in-one assembly tooling station being shown with parts removedfor ease in understanding.

FIG. 3 is an enlarged schematic drawing as enlarged from FIG. 2 to moreclearly show from left-to-right an outer plate, a first intermediatecompactor plate, a main base plate, a second intermediate compactorplate, and an outer pin support plate of the first all-in-one assemblytooling station according to the present invention.

FIG. 4 is an enlarged schematic drawing as enlarged from FIG. 2 to moreclearly show the outer plate, the intermediate compactor plates, themain base plate, and the outer pin support plate of the first all-in-oneassembly tooling station with web-directed elements and compositearticles or lid assemblies being stacked according to the presentinvention.

FIG. 5 is an enlarged schematic drawing as enlarged from FIG. 2 to moreclearly show a downwardly-directed, web-attached lower lid bodyjuxtaposed adjacent an upwardly-directed, post-cut, web-attached supportcone carrier element with upper lid body removed therefrom.

FIG. 6 is an enlarged schematic drawing as enlarged from FIG. 2 to moreclearly show a downwardly-directed, web-attached support cone carrierelement with upper lid body juxtaposed adjacent an upwardly-directed,post-cut, web-based lower lid body-departed aperture.

FIG. 7 is a schematic drawing showing a second production linearrangement with a schematic side view depiction of a second all-in-oneassembly tooling station for punching+trimming+assembling+packaginglower lid bodies and upper lid bodies according to the presentinvention.

FIG. 8 is an enlarged schematic drawing as enlarged from FIG. 7 to moreclearly show the second all-in-one assembly tooling station with firstand second uniformly-directed webs being directed therethrough accordingto the present invention.

FIG. 9 is an enlarged schematic drawing as enlarged from FIG. 7 to moreclearly show a web-attached lower lid body in axial alignment with aweb-attached, support cone carrier element-supported upper lid body.

FIG. 10 is an enlarged schematic drawing showing in greater detail aweb-attached lower lid body in axial alignment with a web-attached,support cone carrier element-supported upper lid body.

FIG. 11 is a schematic drawing showing a third production linearrangement with a schematic side view depiction of a third all-in-oneassembly tooling station for punching-assembling lower lid bodies andupper lid bodies and a separate packaging station for trimming andpackaging composite articles or lid assemblies according to the presentinvention.

FIG. 12 is an enlarged schematic drawing as enlarged from FIG. 11 tomore clearly show the third all-in-one assembly tooling station forpunching-assembling lower lid bodies and upper lid bodies and a separatepackaging station for trimming and packaging the composite articles orlid assemblies.

FIG. 13 is an enlarged schematic drawing as enlarged from FIG. 12 tomore clearly show the third all-in-one assembly tooling station forpunching-assembling lower lid bodies and upper lid bodies withweb-directed elements.

FIG. 14 is a schematic drawing showing a fourth production linearrangement with a schematic side view depiction of a fourth all-in-oneassembly tooling station for punching+trimming+assembling+packaginglower lid bodies and upper lid bodies according to the presentinvention.

FIG. 15 is an enlarged schematic drawing as enlarged from FIG. 14 tomore clearly show from left-to-right an outer plate, a firstintermediate compactor plate, a main base plate, a second intermediatecompactor plate, and an outer pin support plate of the fourth all-in-oneassembly tooling station according to the present invention.

FIG. 16 is an enlarged schematic drawing as enlarged from FIG. 14 tomore clearly show the first and second intermediate compactor platesrelative to opposed portions of the web and the main base plate with thelower lid by to upper lid body assembly site being centrally depicted.

FIG. 17 is a schematic drawing showing a generic fourth production linearrangement with a schematic side view depiction of a generic all-in-oneassembly tooling station (for punching+trimming+assembling+packaginglower lid bodies and upper lid bodies showing the outer plate inengagement with the first intermediate compactor plate.

FIG. 18 is an enlarged schematic drawing as enlarged from FIG. 17 tomore clearly show the outer plate in engagement with the firstintermediate compactor plate

FIG. 19 is a schematic drawing showing a generic fourth production linearrangement with a schematic side view depiction of a generic all-in-oneassembly tooling station for punching+trimming+assembling+packaginglower lid bodies and upper lid bodies showing the outer plate inengagement with the first intermediate compactor plate and the outer pinsupport plate in engagement with the second intermediate compactor platethereby directing the upper lid body into assembled relation with thelower lid body.

FIG. 20 is an enlarged schematic drawing as enlarged from FIG. 19 tomore clearly show from left-to-right an outer plate, a firstintermediate compactor plate, a main base plate, a second intermediatecompactor plate, and an outer pin support plate relative to opposedportions of the web being directed therethrough and the upper lid bodybeing directed into assembled relation with the lower lid body.

FIG. 21 is an enlarged schematic drawing as enlarged from FIG. 19 tomore clearly show the outer plate in engagement with the firstintermediate compactor plate and the outer pin support plate inengagement with the second intermediate compactor plate relative toopposed portions of the web with the upper lid body being directed intoassembled relation with the lower lid body.

FIG. 21A is an enlarged schematic drawing as enlarged from FIG. 21 tomore clearly show the site where the lower lid body punch removes thelower lid body from the web.

FIG. 22 is a schematic drawing showing a generic fourth production linearrangement with a schematic side view depiction of a generic all-in-oneassembly tooling station for punching+trimming+assembling+packaginglower lid bodies and upper lid bodies showing the outer plate beingremoved from engagement with the first intermediate compactor plate andthe outer pin support plate in engagement with the second intermediatecompactor plate with the upper lid body having been directed intoassembled relation with the lower lid body.

FIG. 23 is an enlarged schematic drawing as enlarged from FIG. 22 tomore clearly show from left-to-right an outer plate, a firstintermediate compactor plate, a main base plate, a second intermediatecompactor plate, and an outer pin support plate mechanism relative toopposed portions of the web being directed therethrough with the outerlid body plate with the outer plate being removed from engagement withthe first intermediate compactor plate with the upper lid body havingbeen directed into assembled relation with the lower lid body.

FIG. 24 is an enlarged schematic drawing as enlarged from FIG. 23 tomore clearly show from left-to-right an outer plate, a firstintermediate compactor plate, a main base plate, a second intermediatecompactor plate, and an outer pin support plate mechanism relative toopposed portions of the web being directed therethrough with the outerlid body plate with the outer plate being removed from engagement withthe first intermediate compactor plate and the upper lid body havingbeen directed into assembled relation with the lower lid body.

FIG. 24A is an enlarged schematic drawing as enlarged from FIG. 24 tomore clearly show the site where the lower lid body punch with assembledlid assembly being removed from the first intermediate compactor plate.

FIG. 25 is a schematic drawing showing a generic fourth production linearrangement with a schematic side view depiction of a generic all-in-oneassembly tooling station for punching+trimming+assembling+packaginglower lid bodies and upper lid bodies showing the outer plate beingremoved from engagement with the first intermediate compactor plate andthe outer pin support plate being removed from engagement with thesecond intermediate compactor plate and the second intermediatecompactor plate being removed from engagement with the main base platewith a fully assembled lid assembly being positioned for furtherdirection for stacking with previously assembled lid assemblies.

FIG. 26 is an enlarged schematic drawing as enlarged from FIG. 24 tomore clearly show the outer plate being removed from engagement with thefirst intermediate compactor plate and the outer pin support plate beingremoved from engagement with the second intermediate compactor plate andthe second intermediate compactor plate being removed from engagementwith the main base plate.

FIG. 27 is a top plan view of a first web layout after lower lid bodiesand upper lid bodies are formed via a thermoforming process at athermoforming station and showing a first alternating lower lidbody-upper lid body field presentation and before lower lid bodies andupper lid bodies are die-cut from the web according to the presentinvention.

FIG. 28 is a top plan view of a second web layout after upper lid bodiesare die-cut from the web showing disk-departed web apertures and beforelower lid bodies are die-cut from the web at an assembly tooling stationaccording to the present invention.

FIG. 29 is a top plan view of a third web layout after lower lid bodiesand upper lid bodies are die-cut from the web showing both disk-departedweb apertures and lower lid body-departed apertures in a firstalternating aperture field presentation according to the presentinvention.

FIG. 30 is a top plan view of a fourth web layout after lower lid bodiesand upper lid bodies are formed via a thermoforming process at athermoforming station and showing a second alternating lower lidbody-upper lid body field presentation before lower lid bodies and upperlid bodies are die-cut from the web according to the present invention.

FIG. 31 is a top plan view of a fifth web layout after lower lid bodiesare die-cut from the web showing lower lid body-departed apertures andbefore upper lid bodies are die-cut from the web at an assembly toolingstation according to the present invention.

FIG. 32 is a top perspective view of a fragmentary main base plate andfragmentary upper and lower web portions in exploded relation to oneanother depicting alternating lower lid body and upper lid body forms inthe upper and lower web portions for receipt in the main base plate andin axial alignment.

FIG. 32A is a top perspective view of fragmentary upper and lower webportions in exploded relation to one another depicting alternating lowerlid body and upper lid body forms in the upper and lower web portions inaxial alignment.

FIG. 33 is a top plan view of a sixth web layout after lower lid bodiesand upper lid bodies are die-cut from the web showing both disk-departedweb apertures and lower lid body-departed apertures in a secondalternating aperture field presentation according to the presentinvention.

FIG. 34 is a top plan view of a seventh web layout after lower lidbodies and upper lid bodies are formed via a thermoforming process at athermoforming station and before lower lid bodies and upper lid bodiesare die-cut from the web in a third alternating lower lid body-upper lidbody field presentation according to the present invention.

FIG. 35 is a top plan view of an eighth web layout after a first sectionof two sections of lower lid bodies and upper lid bodies are die-cutfrom the web and before a second section of two sections of lower lidbodies and upper lid bodies are die-cut from the web in the thirdalternating lower lid body-upper lid body field presentation accordingto the present invention.

FIG. 36 is a top plan view of a ninth web layout after first and secondsections of two sections of lower lid bodies and upper lid bodies aredie-cut from the web in a third alternating aperture field presentationaccording to the present invention.

FIG. 37 is a top plan view of the eighth web layout extended to showthree sets of two sections, each set showing a first of two sections oflower lid bodies and upper lid bodies die-cut from the web and before asecond of two sections of lower lid bodies and upper lid bodies aredie-cut from the web in the third alternating lower lid body-upper lidbody field presentation according to the present invention.

FIG. 38 is a first exploded top perspective view of a lid assemblyformed according to the lid assembly methodology of the presentinvention showing an upper lid body or disk in exploded relationrelative to a lower lid body or primary lid formation.

FIG. 39 is a second exploded top perspective view of a lid assemblyformed according to the lid assembly methodology of the presentinvention showing an upper lid body or disk in exploded relationrelative to a lower lid body or primary lid formation.

FIG. 40 is a top perspective view of a lid assembly formed according tothe lid assembly methodology of the present invention showing an upperlid body or disk in assembled relation relative to a lower lid body orprimary lid formation.

FIG. 41 is a first sequential enlarged schematic drawing showing ingreater detail a web-attached lower lid body in axial alignment with aweb-attached, support cone carrier element-supported upper lid bodybeing positioned at the main base plate assembly site.

FIG. 42 is a second sequential enlarged schematic drawing showing ingreater detail a web-attached lower lid body in axial alignment with apost-cut, web-attached, support cone carrier element with upper lid bodyremoved therefrom and positioned at the main base plate assembly site.

FIG. 43 is a third sequential enlarged schematic drawing showing ingreater detail a web-attached lower lid body in axial alignment with apost-cut, web-attached, support cone carrier element with upper lid bodyremoved therefrom and being directed into engagement with the lower lidbody at the main base plate assembly site.

FIG. 43A is a cross-sectional view parallel to the plane of the mainbase plate showing the upper lid body positioned within the disk-guidingshaft of the main base plate as sectioned from FIG. 43.

FIG. 43B is a cross-sectional view orthogonal to the plane of the mainbase plate as sectioned from FIG. 43A.

FIG. 44 is a reduced cross-sectional view orthogonal to the plane of themain base plate depicting alternative methodology according to thepresent invention whereby a series of upper lid bodies or disks arepositioned within the disk-guiding shaft of the main base plate forsequential insertion into lower lid bodies.

FIG. 44A is a cross-sectional view parallel to the plane of the mainbase plate showing the upper lid body positioned within the disk-guidingshaft of the main base plate as sectioned from FIG. 44 to depict adisk-feeding mechanism for feeding the series of upper lid bodies ordisks positioned within the disk-guiding shaft into lower lid bodies.

FIG. 44B is a second enlarged cross-sectional view orthogonal to theplane of the main base plate as enlarged from FIG. 44 depictingalternative methodology according to the present invention whereby aseries of upper lid bodies or disks positioned within the disk-guidingshaft of the main base plate for sequential insertion into lower lidbodies.

FIG. 45 is a cross-sectional view orthogonal to the plane of the firstintermediate compactor plate, the main base plate, the secondintermediate compactor plate, and the outer plate depicting alternativemethodology whereby a series of upper lid bodies or disks are positionedwithin the disk-guiding shaft of the main base plate for sequentialinsertion into lower lid bodies and the first and second intermediatecompactor plates are in engagement with the main base plate.

FIG. 45A is an enlarged cross-sectional view orthogonal to the plane ofthe main base plate as enlarged from FIG. 45 to depict in greaterclarity the structures otherwise depicted in FIG. 45.

FIG. 46 is a cross-sectional view orthogonal to the plane of the mainbase plate depicting a staggered arrangement of lower lid bodies andupper lid bodies on the web in a pre-assembly position with axiallyaligned lower lid bodies and upper lid bodies in side-by-side relation,and the outer plates in partial engagement with the first and secondintermediate compactor plates.

FIG. 47 is an enlarged cross-sectional view as enlarged from FIG. 46 toshow in greater clarity the structures associated with the main baseplate otherwise depicted in FIG. 46.

FIG. 48 is an enlarged cross-sectional view as enlarged from FIG. 46 toshow in greater clarity the structures associated with the outer plateand the first intermediate compactor plate otherwise depicted in FIG.46.

FIG. 49 is an enlarged cross-sectional view as enlarged from FIG. 46 toshow in greater clarity the structures associated with the secondintermediate compactor plate and the outer plate and otherwise depictedin FIG. 46.

FIG. 50 is a cross-sectional view orthogonal to the plane of the mainbase plate depicting a staggered arrangement of lower lid bodies andupper lid bodies on the web in a pre-assembly position with axiallyaligned lower lid bodies and upper lid bodies in side-by-side relation,and the outer plates disengaged from the first and second intermediatecompactor plates.

FIG. 51 is an enlarged cross-sectional view as enlarged from FIG. 50 toshow in greater clarity the structures associated with the main baseplate and first and second intermediate compactor plates otherwisedepicted in FIG. 50.

FIG. 51A is an enlarged cross-sectional view as enlarged from FIG. 51 toshow in greater clarity the structures associated with circular cuttingmechanism associated with the main base plate otherwise depicted in FIG.51.

FIG. 52 is an enlarged cross-sectional view as enlarged from FIG. 51 toshow in greater clarity the structures associated with the compactorshaft and the compactor head relative to the main base plate asotherwise depicted in FIG. 51.

FIG. 52A is an enlarged cross-sectional view as enlarged from FIG. 52 toshow in greater clarity the structures associated with the compactorshaft and the compactor head relative to the main base plate asotherwise depicted in FIG. 52.

FIG. 53 is a cross-sectional view orthogonal to the plane of the mainbase plate depicting a staggered arrangement of lower lid bodies andupper lid bodies on the web in a pre-assembly position with axiallyaligned lower lid bodies and upper lid bodies in side-by-side relation,the precision alignment of lower lid body and upper lid body completeand the outer plates and first and second intermediate compactor platesbeing in a pre-punch position.

FIG. 54 is an enlarged cross-sectional view as enlarged from FIG. 53 toshow in greater clarity the structures associated with the compactorshaft and the compactor head relative to the main base plate asotherwise depicted in FIG. 53.

FIG. 55 is a cross-sectional view orthogonal to the plane of the mainbase plate depicting a staggered arrangement of lower lid bodies andupper lid bodies on the web in an assembly position with axially alignedlower lid bodies and upper lid bodies in side-by-side relation.

FIG. 56 is an enlarged cross-sectional view as enlarged from FIG. 55 toshow in greater clarity the structures associated with the compactorshaft and the compactor head relative to the main base plate asotherwise depicted in FIG. 55.

FIG. 56A is an enlarged cross-sectional view as enlarged from FIG. 56 toshow in greater clarity the structures associated with the compactorshaft and the compactor head relative to the main base plate asotherwise depicted in FIG. 56.

FIG. 57 is an enlarged cross-sectional view as enlarged from FIG. 55 toshow in greater clarity the structures associated with a circularcutting mechanism relative to the compactor shaft, the compactor head,and the main base plate as otherwise depicted in FIG. 55.

FIG. 58 is an enlarged cross-sectional view as enlarged from FIG. 55 toshow in greater clarity the structures associated with end portions ofthe compactor shaft as associated with the first intermediate compactorplate and the compactor push pin associated with the outer plate asotherwise depicted in FIG. 55.

FIG. 59 is an enlarged cross-sectional view as enlarged from FIG. 55 toshow in greater clarity the structures associated with the circularcutting mechanism relative to the main base plate as otherwise depictedin FIG. 55.

FIG. 60 is a cross-sectional view orthogonal to the plane of the mainbase plate depicting a staggered arrangement of lower lid bodies andupper lid bodies on the web in a post assembly position with axiallyaligned lower lid bodies and upper lid bodies in side-by-side relation.

FIG. 61 is an enlarged cross-sectional view as enlarged from FIG. 60 toshow in greater clarity the structures associated with the compactorshaft and the compactor head to the main base plate as otherwisedepicted in FIG. 60.

FIG. 62 is an enlarged cross-sectional view as enlarged from FIG. 60 toshow in greater clarity the structures associated with the lid supportbody with an assembled lid assembly as otherwise depicted in FIG. 60.

FIG. 63 is a cross-sectional view orthogonal to the plane of the mainbase plate depicting a staggered arrangement of lower lid bodies andupper lid bodies on the web in a newly indexed pre-assembly positionwith axially aligned lower lid bodies and upper lid bodies inside-by-side relation.

FIG. 64 is an enlarged cross-sectional view as enlarged from FIG. 63 toshow in greater clarity the structures associated with newly indexedlower lid body and upper lid body positions relative to the main baseplate as otherwise depicted in FIG. 63.

FIG. 65 is a cross-sectional view orthogonal to the plane of the mainbase plate (as sectioned from FIG. 66) to depict a staggered arrangementof lower lid bodies and upper lid bodies on the web with the first andsecond intermediate compactor plates in engagement with the main baseplate and assembled lid assembles being removed from the lid supportbodies via lid stripper elements or steps associated with theintermediate compactor plates.

FIG. 66 is an enlarged view of the all-in-one assembly otherwisedepicted in FIG. 1 to show in greater clarity post lid assembly activitywhereby newly formed lid assemblies are directed down chutes to apackaging station.

FIG. 67 is an enlarged cross-sectional view as enlarged from FIG. 65 toshow in greater clarity assembled lid assembles being removed from thelid support bodies via lid stripper elements or steps associated withthe intermediate compactor plates as otherwise depicted in FIG. 65.

FIG. 67A is an enlarged cross-sectional view as enlarged from FIG. 67 toshow in greater clarity the compactor head retreated into the compactorhead nest with a disk already punched for the next assembly as otherwisedepicted in FIG. 67.

FIG. 68 is an elevational side view depiction of an alternative toolsystem according to the present invention for cutting lid bodies fromstacked web sheets showing a tubular shaft, a shaft-receiving plateassembly, and a stack of web sheets.

FIG. 69 is a first top perspective view of the alternative tool systemaccording to the present invention for cutting lid bodies from stackedweb sheets showing the tubular shaft, the shaft-receiving plateassembly, and the stack of web sheets.

FIG. 70 is a second top perspective view of the alternative tool systemaccording to the present invention for cutting lid bodies from stackedweb sheets showing the tubular shaft with parts broken away to show aninner stack of cut lid formations; the shaft-receiving plate assembly,and the stack of web sheets with workpieces.

FIG. 71 is a third top perspective view of the alternative tool systemaccording to the present invention for cutting lid bodies from stackedweb sheets showing the tubular shaft; the shaft-receiving plate assemblywith parts broken away to show the end of the tubular shaft; and thestack of web sheets.

FIG. 71A is an enlarged, fragmentary sectional view as enlarged andsectioned from FIG. 71 to show in greater clarity the end of the tubularshaft engaging an upper most web sheet from the stack of web sheets.

FIG. 72 is a first sequential side view depiction of the alternativetool system according to the present invention for cutting lid bodiesfrom stacked web sheets showing the tubular shaft with parts broken awayto show an inner stack of cut lid formations and external threads; ashaft-receiving plate assembly with parts broken away to show the end ofthe tubular shaft and a stack of web sheets positioned in inferioradjacency to the shaft-receiving plate assembly.

FIG. 73 is a second sequential side view depiction of the alternativetool system according to the present invention for cutting lid bodiesfrom stacked web sheets showing the tubular shaft with parts broken awayto show an inner stack of cut lid formations and external threads; ashaft-receiving plate assembly; and a stack of web sheets positioned ininferior adjacency to the shaft-receiving plate assembly, the end of thetubular shaft having been driven through the stack of web sheets via theshaft-receiving plate assembly.

FIG. 74 is a side view depiction of the tubular shaft positionedrelative to a fragmentary shaft-receiving plate assembly with partsbroken away to show the end of the tubular shaft as positioned insuperior adjacency to a stack of web sheets.

FIG. 74A is an enlarged sectional view as enlarged and sectioned fromFIG. 74 to show in greater clarity the end of the tubular shaftoutfitted with a cutting implement for cutting through the stack of websheets

FIG. 75 is a side view depiction of the tubular shaft of the alternativetool system according to the present invention.

FIG. 75A is an enlarged sectional view as enlarged and sectioned fromFIG. 75 to show in greater clarity the end of the tubular shaftoutfitted with a cutting implement for cutting through a stack of websheets.

FIG. 76 is an enlarged first sequential schematic depiction of acompactor head adjustment mechanism according to the present invention,the adjustment mechanism being shown before the compactor head isadjusted.

FIG. 77 is an enlarged second sequential schematic depiction of thecompactor head adjustment mechanism according to the present invention,the adjustment mechanism being shown after the compactor head isadjusted.

FIG. 78 is a top depiction showing relative diameters of a resilientupper lid body or disk material construction in both actuated andrelaxed states.

FIG. 79 is a schematic depiction of an actuated upper lid body or diskbeing removed from a disk-guiding shaft and returning to a relaxedmaterial configuration from an actuated (compressed) materialconfiguration.

FIG. 80 is a top perspective view of a generic “turn table” compositearticle assembled in-line with an alternative assembly line arrangementaccording to the present invention from four individual web-carriedelements.

FIG. 81 is an exploded top perspective view of the generic “turn table”composite article assembled in-line with the alternative assembly linearrangement according to the present invention depicting four individualcomposite elements in axial alignment with one another for assembly.

FIG. 82 is a first top view of the generic “turn table” compositearticle for assembly in-line with the alternative assembly linearrangement according to the present invention.

FIG. 83 is an exploded side elevational view of the generic “turn table”composite article for assembly in-line with the alternative assemblyline arrangement according to the present invention depicting fourindividual composite elements in axial alignment with one another.

FIG. 84 is an enlarged, exploded, cross-sectional side view of thegeneric “turn table” composite article for assembly in-line with thealternative assembly line arrangement according to the present inventionas sectioned from FIG. 82 to depict in greater detail the fourindividual composite elements in axial alignment with one another.

FIG. 85 is a second top view of the generic “turn table” compositearticle as assembled in-line with the alternative assembly linearrangement according to the present invention.

FIG. 86 is an edge view of the generic “turn table” composite article asassembled in-line with the alternative assembly line arrangementaccording to the present invention.

FIG. 87 is an enlarged, cross-sectional view of the generic “turn table”composite article assembled in-line with the alternative assembly linearrangement according to the present invention as sectioned from FIG. 85to depict in greater detail the four individual composite elements inaxial alignment with one another as assembled.

FIG. 88 is a schematic drawing depicting the relative position of afirst set of four individual web-carried downwardly composite elementsas juxtaposed opposite a second set of four individual web-carriedupwardly directed composite elements and depicting axial alignments ofthe first and second individual composite elements at upper and lowerportions of the figure.

FIG. 89 is a first sequential schematic drawing of a continuous web withweb-carried individual composite elements and supporting mechanizedassembly station tooling with a loop mechanism and depicting a firstcomposite element after looping through the loop mechanism in axialalignment with a second composite element as axially aligned at a firstalignment cavity of the mechanized assembly station tooling forsecond-to-first composite element assembly.

FIG. 89A is an enlarged fragmentary view as enlarged from FIG. 89 toshow in greater detail the axial alignment of the first and secondcomposite elements at the first alignment cavity.

FIG. 90 is a second sequential schematic drawing of a continuous webwith web-carried individual composite elements and supporting mechanizedassembly station tooling with a loop mechanism and depicting the secondcomposite element in axial alignment with the first composite element atthe first alignment cavity of the mechanized assembly station tooling asdeparted from the web and directed toward the first composite elementfor second-to-first element assembly for forming a web-carriedsecond-first element composite or basic composite.

FIG. 90A is an enlarged fragmentary view as enlarged from FIG. 90 toshow in greater detail the axial alignment of the first and secondcomposite elements at the first alignment cavity with the secondcomposite element departing the web and being directed along analignment axis toward the first composite element for forming theweb-carried second-first element composite or basic composite.

FIG. 91 is a third sequential schematic drawing of a continuous web withweb-carried individual composite elements and supporting mechanizedassembly station tooling with a loop mechanism and depicting a thirdcomposite element in axial alignment with the second-first elementcomposite at a second alignment cavity of the mechanized assemblystation tooling as departed from the web and directed toward thesecond-first element composite for third element-to-second-first elementcomposite assembly for forming a web-carried third-second-first elementcomposite.

FIG. 91A is an enlarged fragmentary view as enlarged from FIG. 91 toshow in greater detail the axial alignment of the third compositeelement and the second-first element composite at a second alignmentcavity with the third composite element departing the web and beingdirected along an alignment axis toward the second-first elementcomposite for forming the web-carried third-second-first elementcomposite.

FIG. 92 is a fourth sequential schematic drawing of a continuous webwith web-carried individual composite elements and supporting mechanizedassembly station tooling with a loop mechanism and depicting a fourthcomposite element in axial alignment with the third-second-first elementcomposite at a third alignment cavity of the mechanized assembly stationtooling as departed from the web and directed toward thethird-second-first element composite for fourth compositeelement-to-third-second-first element composite assembly for forming aweb-carried fourth-third-second-first element composite.

FIG. 92A is an enlarged fragmentary view as enlarged from FIG. 92 toshow in greater detail the axial alignment of the fourth compositeelement and the third-second-first element composite at a thirdalignment cavity with the fourth composite element departing the web andbeing directed along an alignment axis toward the third-second-firstelement composite for forming the web-carried fourth-third-second-firstelement composite.

FIG. 93 is a fifth sequential schematic drawing of a continuous web withweb-carried individual composite elements and supporting mechanizedassembly station tooling with a loop mechanism and depicting thefourth-third-second-first element composite being departed from the webfor providing the generic “turn table” composite article otherwisedepicted in FIGS. 80-87.

FIG. 93A is an enlarged fragmentary view as enlarged from FIG. 93 toshow in greater detail the generic “turn table” composite article beingdeparted from the element-carrying web.

FIG. 94 is a sixth sequential schematic drawing of an optionalcontinuous web with web-carried individual composite elements andsupporting mechanized assembly station tooling with first and second lopmechanisms and depicting a first fourth-third-second-first elementcomposite being conveyed along the web toward the second loop mechanismwith an alignment axis extending in a first direction and a secondfourth-third-second-first element composite being conveyed along the webaway from the second loop mechanism with a 90-degree twist in the webconveyor for re-orienting the alignment axis of the secondfourth-third-second-first element composite in a second directionorthogonal to the first direction for successive composite assembly at afourth alignment cavity.

FIG. 95 is a perspective view of a press frame with die setup and acontinuous web conveyor being directed therethrough and looping througha diagrammatic loop mechanism with exemplary individual compositeelements being shown in a first portion of the web conveyor beforeentering the loop mechanism as directed through a first die portion ofthe press frame and exposed elemental voids being shown in a secondportion of the web conveyor after leaving the loop mechanism as directedthrough a second die portion of the press frame.

FIG. 96 is a side view of the press frame with die setup otherwisedepicted in FIG. 95 with the continuous web conveyor being directedtherethrough and looping through a diagrammatic loop mechanism withexemplary individual composite elements being shown conveyed by thefirst portion of the web conveyor toward the loop mechanism as directedthrough a first die portion of the press frame and the second portion ofthe web conveyor in parallel relation to the first portion after leavingthe loop mechanism as directed through a second die portion of the pressframe.

FIG. 97 is a top view of the press frame with die setup otherwisedepicted in FIG. 95 with the continuous web conveyor being directedtherethrough with a first portion of the web conveyor being directedthrough a first die portion of the press frame and a second portion ofthe web conveyor in parallel relation to the first portion beingdirected through a second die portion of the press frame andunidirectional movement depiction of the press frame assembly.

FIG. 98 is a sectional view of the press frame with die setup otherwisedepicted in FIG. 96 sectioned to show otherwise hidden cavities formedin plates of the die setup within the press frame.

FIG. 98A is a fragmentary enlarged sectional view as enlarged andsectioned from FIG. 98 to show in greater detail alignment cavitiesformed in the alignment plate of the die setup of the press frame.

DETAILED DESCRIPTION OF THE PREFERRED SYSTEM AND METHODOLOGY

Referring now to the drawings with more specificity, the followingspecifications generally describe certain systemic production linearrangements and methods of forming composite articles or two-workpieceassemblies supported thereby as well as certain methods for precisionpart adjustments, including part-trimming methods. The production linearrangements and methods of composite article formation according to thepresent invention preferably involve single station or so-called“all-in-one” mechanized assembly station tooling methodology. Acontinuous web 20 carries web blanks through a thermoforming station 100for forming lower lid bodies or primary lid formations as at 10 andupper lid bodies or disks as at 19 (i.e. first and second workpieces 10and 19, respectively) for further delivery to a proprietary die setupwithin a press assembly.

The upper lid bodies or disks 19 are carried by a support cone carrierelement 11 (the support cone carrier element with attached disk element19 is referenced at 11). The upper lid bodies or disks 19 are insertableinto the lower lid bodies or primary lid formations 10 for assembly intolid assemblies 13. The upper lid bodies or disks 19 are removed from theweb 20 via the single tooling station assembly methodology as carried bythe support cone carrier element 11. Once the disks 19 are removed fromthe support cone carrier element 11, the support cone carrier element isreferenced at 12 as generally illustrated and referenced in introductoryFIGS. 1 and 2.

Before entry into the all-in-one, mechanized assembly station tooling(comprising manufacturing components and/or mechanized machineryrequired for production, including die configurations setup within apress frame assembly), the lower lid bodies or primary lid formations 10and/or upper lid bodies or disks 19 may preferably be directed through apre-punch station as at 101 for die-cutting or punching sip holes, airvents, or other secondary apertures therein. The lower lid bodies orprimary lid formations 10 and the upper lid bodies or disks 19,supported and carried by the support cone carrier elements 11, arearranged on the web 20 in spaced relation to one another in analternating manner as generally depicted in FIGS. 1, 2, 4, 7, 11, 12,13, 14, 17, 19, 22, and 25.

The web 20 carrying the lower lid bodies or primary lid formations 10and the upper lid bodies or disks 19 is preferably directed through aloop mechanism 102 in certain preferred embodiments such thatalternating lower lid bodies or primary lid formations 10 and upper lidbodies or disks 19 are directed into axial alignment (as at assemblyalignment axis 110) with one another for assembly of the upper lidbodies or disks 19 into the lower lid bodies or primary lid formations10 during a single cutting and disk-to-lid insertion movement.

In this regard, and central to the practice of the present invention, isa substantially simultaneous, dual-action (with sequential momentarydelays as may be required), cut-from-web and disk-to-lid or workpiece toworkpiece assembly step. In other words, when the upper lid body or disk19 is cut from the web 20, it is directed (e.g. pushed (i.e. notcarried)) into assembled relation with the lower lid body or primary lidformation 10 also being separated (e.g. cut) from the web 20 during oneclap-like, to-and-fro, or back and forth tooling movement within theall-in-one assembly tooling station(s) or mechanized assembly stationtooling according to the present invention.

As prefaced above, the upper lid bodies or disks 19 are never carriedfor later assembly with the lower lid bodies or primary lid formations10, but directed axially after being removed from the web 20 intoassembled relation with the lower lid bodies or primary lid formations10. The assembled lower lid bodies or primary lid formations 10 andupper lid bodies or disks 19 thus form lid assemblies 13, which lidassemblies 13 are collected and preferably directed into a stackedrelation or manner as generally depicted in FIGS. 1, 2, 4, 7, 11, 12,14, 17, 19, 22, and 25 for packaging purposes. These basic productionline principles are generally demonstrated in introductory FIGS. 1 and2.

After the dual cutting-assembling action of the all-in-one assemblystation tooling, the disk-departed support cone carrier elements 12(i.e. support cone carrier element without disk 19) of the web 20continue in the web flow direction of the web 20 with disk-departedapertures as at 22 in alternating relation with lower lid body-departedapertures as at 23. A series of upper lid bodies or disks 19 andassociated disk-departed apertures or disk holes 22; and lower lidbodies 10 and associated lower lid body-departed apertures or lid holes23 are comparatively illustrated and referenced in FIGS. 27-37 as beingcircular in formation, but such circular shapes are exemplary for easeor brevity of illustration. Other aperture shapes are contemplated asfalling within the ambit of these specifications and inventive conceptsbeing described.

Further comparatively referencing FIGS. 1-6, the reader will thereconsider an introductory or first production line arrangement with aschematic side view depiction of a first all-in-one assembly toolingstation for punching+trimming+assembling+packaging lower lid bodies 10and upper lid bodies 19 according to the present invention. The firstexemplary production line arrangement shows a thermoforming station asat 100, a pre-trimming station as at 101 (for forming or punching sipholes, air holes, and/or other secondary aperture formations); and afirst all-in-one assembly tooling station or mechanized assembly stationtooling for lower lid bodies or primary lid formations 10 and upper lidbodies or disks 19 (initially supported by support cone carrier elements11) as arranged on the web 20 in alternating rows as otherwise variouslyand comparatively depicted in FIGS. 27-37.

It will be understood from a comparative consideration of FIGS. 27-37that the present invention contemplates multiple variations ofalternating rows of multiple lower lid bodies or primary lid formations10 and upper lid bodies or disks 19 as well as singularly alternatingrows of singular lower lid bodies or primary lid formations 10 and upperlid bodies or disks 19. For example, it is contemplated that fiveconsecutive rows of lower lid bodies or primary lid formations 10 mayalternate with a corresponding five consecutive rows of upper lid bodiesor disks 19. Top perspective depictions of an exemplary upper lid bodyor disk 19 relative to an exemplary lower lid body or primary lidformation 10 are generally and comparatively depicted in FIGS. 38-40.

In such an arrangement, each print of five consecutive rows of lower lidbodies or primary lid formations 10 will advance through thedisk-punching side of the all-in-one assembly tooling stationrepresented on the left side of FIGS. 1, 2, 3, and 4 and then flip overthrough the loop mechanism 102 to be indexed in at the lid side of theall-in-one assembly tooling station shown on the right side. At the sametime, a print of five consecutive rows of upper lid bodies or disks 19may be indexed in on the disk-punching side of the all-in-one assemblytooling station, shown on the left. Effectively, the all-in-one assemblytooling station will align five consecutive rows of upper lid bodies ordisks 19 against a corresponding five consecutive rows of lower lidbodies or primary lid formations 10.

Referencing FIG. 3, the reader will there consider a firstrepresentative all-in-one assembly tooling station according to thepresent invention. The outer pin support plate 16 comprises a compactorpush pin as at 49. The outer pin support plate 16 opposes a firstintermediate compactor plate 14 with a compactor shaft 17 with acompactor head 18 in axial alignment with the compactor push pin 49. Thecompactor shaft 17 preferably comprises a compactor push pinvacuum/pressure access channel or tunnel 48. The first intermediatecompactor plate 14 opposes a centrally-located immovable or stationarymain base plate 30, which main base plate 30 is the site of upper lidbody 19 to lower lid body 10 assembly via access opening 42 of thesecond intermediate compactor plate 14.

The second intermediate compactor plate 14 opposes the main base plate30 and interfaces between the main base plate 30 and an outer plate 15having a lid support base 46 and a lid support body 45. The reader willnote that the (arcuate) disk 19 is insertable into a lid depression 21(thermo)formed in the lower lid body 10 via the (arcuate) compactor head18, which lid depression 21 comprises a rear or inner depression surface40 (opposing a lid support depression top surface 41) and a top or outerdepression surface. The compactor head 18 opposes inner or rear disksurface and the outer or frontal disk surface opposes the rear or innerdepression surface when the lower lid bodies 10 and the upper lid bodies19 are placed into axial alignment for forming lid assemblies 13.

Comparatively referencing FIGS. 3 and 4, the reader will further notethat the (continuous) web 20 travels intermediate the first and secondintermediate compactor plates 14 and the main base plate 30 for axiallyaligning the lower lid bodies 10 and the upper lid bodies or disks 19within the assembly cavity of the main base plate 30, characterized bycomprising a conical countersink chamber or portion as at 54, adisk-guiding shaft as at 56, and a lid nest as at 31. In the firstexemplary production line arrangement, the web 20 travels in a firstdirection intermediate the first intermediate compactor plate 14 and themain base plate 30; loops as at loop mechanism 102; and travels in asecond direction opposite the first direction intermediate the main baseplate 30 and the second intermediate compactor plate 14. In the firstproduction line arrangement depicted in FIG. 3, assembled lid assemblies13 may exit the second intermediate compactor plate 14 and be directedto a packaging site or station of the all-in-one assembly toolingstation where successive lid assemblies 13 are further re-directed intostacked relation.

Comparatively referencing FIGS. 2 and 5, the reader will see that upperlid bodies or disks 19 traversing the first intermediate compactor plate14 and main base plate 30 are removed from the support cone carrierelements 11 such that when support cone carrier elements 12 (withoutdisks 19) traverse the loop mechanism 102 and pass lower lid bodies 10just passing the first intermediate compactor plate 14 and main baseplate 30, disk-departed apertures 22 are fleetingly in axial alignmentwith the lid depressions 21, which lid depressions 21 may be preferablyprovided with a lid sip hole 68 as preferably pre-punched via thepre-punch station 101. Comparatively referencing FIGS. 2 and 6, thereader will see that support cone carrier elements 11 (with disks 19)prior to entry through the first intermediate compactor plate 14 andmain base plate 30 are fleetingly in axial alignment with lower lidbody-departed apertures 23 formed after assembly of the lid assemblies13.

Comparatively referencing FIGS. 7-10, the reader will consider a secondproduction line arrangement with a schematic side view depiction of asecond all-in-one station for punching+trimming+assembling+packaginglower lid bodies or primary lid formations 10 and upper lid bodies ordisks 19 according to the present invention. The second production linearrangement according to the present invention provides twothermoforming stations 100 and two pre-trimming or pre-punching stations101 (for forming or punching sip holes, air holes, and/or othersecondary aperture formations) with two webs 20 (e.g. differentlycolored webs 20) being directed therethrough in a uniform direction fromopposite sides of the same all-in-one assembly tooling station therebyeliminating the loop mechanism 102.

The second production line arrangement according to the presentinvention is believed highly beneficial for high volume production inwhich composite articles or two-piece lid assemblies 13 are provided intwo alternating colors (i.e. lower lid bodies or primary lid formations10 provided with first coloration and upper lid bodies or disks 19provided with second coloration different than the first coloration).For example, the application may call for white lower lid bodies orprimary lid formations 10 with black upper lid bodies or disks 19, andvice versa. If a first thermoforming station 100 forms lower lid bodies10 and upper lid bodies 19 from a web 20 with first coloration, thesecond thermoforming station 100 may form lower lid bodies 10 and upperlid bodies 19 with second coloration.

Comparatively referencing FIGS. 7 and 9, the reader will see that asupport cone carrier element 11 (with upper lid body or disk 19) of afirst web 20 and a lower lid body 10 of a second web 20 opposite thefirst web 20 are positioned into fixed axial alignment (as at assemblyalignment axis 110) as both the upper lid body 19 and lower lid body 10traverse the first and second intermediate plates 14 and the main baseplate 30 for disk-to-lid assembly. FIG. 8 further introduces the lidsupport body 45 as structurally situated atop the lid support base 46via springs 58, and as connected to the outer plate 15. Comparativelyreferencing FIGS. 9 and 10, the reader will preliminarily consider adisk die opening limit as at 47 and the disk-guiding shaft as at 56formed in the main base plate 30 for enhancing axially aligned deliveryof the disk 19 into the lid depression 21. It is contemplated that theall-in-one assembly tooling station(s) according to the presentinvention are so productive as to adequately serve two high-speedthermoforming stations 100 simultaneously. In this regard, it is notedthat bottlenecking within state-of-the-art thermoforming processes doesnot occur at the thermoforming stations, but rather at the subsequenttrimming and assembly tooling stations down-web.

Referencing FIGS. 11-13, the reader will there consider a thirdproduction line arrangement according to the present invention showing athird all-in-one assembly tooling station as at 103 for punch-assemblinglower lid bodies 10 and upper lid bodies 19 and a separate packagingstation as at 104 for trimming and packaging assembled two-piece lidassemblies 13. In other words, the production line arrangement generallydepicted in FIGS. 11-13 shows assembled lid assemblies 13 firstlytrimmed using the basic punch and die method as a separate assemblytooling station located on the way to the loop mechanism 102 after theupper lid body or disk 19 is simultaneously punched-inserted into thelower lid body or primary lid formation 10 lid via the all-in-oneassembly tooling station 103.

In this regard, the reader will note that web 20 with upper lid bodiesor disks 19 being carried by support cone carrier elements 11 proceedsthrough the loop mechanism 102 to flip over and feeds into the oppositeside of all-in-one assembly tooling station 103 for subsequent andsimultaneous punching and insertion of the upper lid bodies or disks 19into the lower lid body or primary lid formations 10. The secondtrimming-packaging station 104 receives assembled lid assemblies 13 fromthe web 20 after being processed by the all-in-one assembly toolingstation 103.

In other words, the all-in-one assembly tooling station 103 punches theupper lid body or disk 19 from the support cone carrier element 11thereafter assembling the upper lid body or disk 19 into the lower lidbody or primary lid formation 10 while still on the web 20 orweb-attached after advancing through the loop mechanism 102. The dualaction die-cut and directed movement of the upper lid body or disk 19into engagement with the lid depression 21 of the lower lid body orprimary lid formation 10 allows for increased efficiency of assemblingthe upper lid bodies or disks 19 into the lower lid bodies or primarylid formations 10 without the requirement for temporarily holding orcarrying the disk 19 and/or moving it by changing directions asgenerally described by state-of-the-art systems and methods.

Referencing FIGS. 14-25, the reader will there consider certainproduction lines according to the present invention whereby theall-in-one assembly tooling stations separate the lower lid bodies orprimary lid formations 10 and upper lid bodies or disks 19 from the web20 utilizing punch and die methods as opposed to certain circular knifemethodology otherwise practiced, in part, by the all-in-one assemblytooling stations depicted in FIGS. 1-10 discussed in more detail laterin these specifications. Lower lid body 10 and upper lid body 19 webarrangements (with associated aperture arrangements) depicted in FIGS.14-25 are further generally and variously depicted in various plan viewsin FIGS. 27-31 and 33-37 with perspective views being presented in FIGS.32 and 32A.

The embodiments depicted in FIGS. 14-25 show methods of trimmingassembled lid assemblies 13 by the punch and die incorporated intoall-in-one assembly tooling station(s). One of the structural reasons itis possible to incorporate a punch and die method of trimming into theall-in-one assembly tooling stations depicted in the FIGS. 14-25 set ofdrawings is because all relevant parts (e.g. the lower lid bodies 10,the upper lid bodies 19; the intermediate compactor plates 14, the outerplates 15, the outer pin support plates 16, the main base plate 30, thecompactor shaft 17, and the compactor head 18) are tightly aligned andin a pressed-against-each other state as perhaps most clearly depictedin FIG. 23.

The die-cut type lid trimming process begins when the web 20 isimmovably pressed between the intermediate compactor plates 14 and themain base plate 30. The upper lid body or disk 19 is trimmed-insertedinto the lower lid body or primary lid formation 10. The lid punch 60 isattached to the outer plate 15 and the lid support body 45 is suspendedvia springs 58 on the top of the lid punch 60 as generally depicted inFIGS. 14-23. The outer plate 15 with lid punch 60 moves towards thesecond intermediate compactor plate 14 and the lid punch 60 with lidsupport body 45 passes through access opening 42 of plate 9. Theprepositioned lower lid body 10 on the web 20 is pressed intocountersink-shaped lid nest 31 by the conically shaped lid support body45.

The combination of conically shaped walls of the lid support body 45, assuspended from the lid punch 60 on springs 58, allows the lid supporttop surface 33 and the lid support rim top 35 to touch correspondingsurfaces of the lid top rear surface 38 and lid ring rear surface 36before the lid top outer surface 39 touches the lid nest ceiling 32. Thelid rim outer surface 37 touches the lid nest rim surface 34 before theweb 20 is securely pressed between the main base plate 30 and the secondintermediate compactor plate 14.

The precision adjustment of alignment happens the moment before thelower lid body 10 and the web 20 are immovably pressed between the mainbase plate 30 and the second intermediate compactor plate 14 and the lidpunch 60 is pressed against the back surface of the lower lid body 10and the lid punch 60 cutting edge 61 is pressed against the lid edgeperimeter 62. The lid punch 60 trims the lower lid boy 10 out of the web20 and pushes it to the limit of lid die opening 65 at the same timepressing the lower lid body 10 further into the lid nest 31.

The trimmed lid assembly 13 is immovably pressed between the lid nestsurface 31 and the surface of lid support body 45 and the springs 58 arecompressed and the lid punch 60 is pressed against the bottom of the lidsupport body 45. The upper lid body or disk 19 is trimmed and pushed bythe compactor head 18 into the lid depression 21 as generally depictedand referenced in FIGS. 19-21. At that moment the outer plate 15 withlid punch 60 and suspended lid support body 45 reverses direction andstarts moving back.

Simultaneously, the compactor shaft 17 continues advances forward untilcompactor head 18 pushes the lid edge perimeter 62 of the trimmed lidassembly 13 beyond the plane of the web 20 through lower lidbody-departed aperture 23 (the lid hole or lower lid body-departedaperture 23 is formed on the web 20 after the lower lid body 10 ispunched therefrom) to the compactor's assembly push limit 25 of thecompactor shaft 17 as generally depicted in FIG. 21 at broken line C.The compactor moving distance is from line A to line D in FIGS. 23 and24. The reader will note that the final push to the limit 64 as depictedin FIGS. 23 and 24 (at distance Y as further referenced in FIG. 58) isonly needed if the lower lid body 10 (to form lid assembly 13) ispunched out with conventional punch and die method as described anddepicted in FIGS. 22-24. If a circular cutting mechanism is implemented,the requirement for such a final push becomes optional. In such a case,the lid assembly 13 is pulled out by lid support body 45, possibly by avacuum directive to help hold lid assembly 13 on lid support body 45.Additionally, the “final” push to “Y” by push pin 49 is not required.

As the outer plate 15 (as an extended plate portion of the outer pinsupport plate 16) with the lid punch 60 continues reversing movement,the access opening plate 9 (as an extended plate portion of the first orsecond intermediate compactor plate 14) also starts moving in reversedirection (as generally illustrated in FIGS. 46-67A). The punched outand assembled lid assembly 13 remains positioned on the lid support body45 preferably held by vacuum or mechanical means.

The access opening plate 9 moves in reverse direction until the lidassembly 13 is removed from the lid support body 45 by the lid stripperelement or step 43 as generally depicted in FIGS. 16 and 18. FIG. 16depicts the lid assembly 13 as removed from the lid support body 45 whenthe lid perimeter edge 62 touches the lid stripper element or step 43.FIG. 15 depicts the lid assembly 13 directed to the packaging station.Transport or directed movement of the lid assembly 13 to the packagingstation may be achieved mechanically or with the aid of a vacuum orpressure-applying device or mechanism (not specifically illustrated).

Simultaneously, the first intermediate compactor plate 14 with compactorshaft 17, the disk punch 50, and the outer pin support plate 16 withpush pin 49 reverses direction and starts moving to the positiongenerally depicted in FIGS. 25 and 26. The reader will note that thetrimmed lid assembly 13 may be pushed out of the lid nest 31 andtherebeyond not only by the compactor shaft 17 but also by othermechanical means such as a ring element operable to push the lid rimouter surface 37 to further direct the lid assembly 13 for redirectionto the packaging station whereby lid assemblies 13 may preferably beplaced into stacked relation. The reader will further note that thecompactor shaft 17 and compactor head 18 may preferably comprisevacuum/pressure delivery means via vacuum/pressure access shaft orchannel 48. The application of vacuum/pressure is contemplated ascomplimentary to help with disk 19 discharge by way of the compactorhead 18 or enhancing adhesion of the disk 19 surface to the surface ofthe compactor head 18.

The functional part movements within the all-in-one assembly toolingstation(s) happen simultaneously or nearly simultaneously in a tightlysynchronized manner in relatively short periods of time, such that afull cycle is possibly as short as half a second. The drawings submittedin support of these specifications do not precisely depict the exactsequence of each function, but rather attempt to depict the relativeposition of different parts during the process of performing aparticular function of all-in-one assembly tooling station. In general,plates 9/14 and 15/16 move in synchronized manner, simultaneously in adirection towards the stationary main base plate 30 and in reversedirection back to the starting point. In this way, the clap-like orclapping movement and the moniker “clapper” may be said to fairly andaccurately describe plate movement character.

Referring now to FIGS. 41-45A, the reader will recall comparativelyreferencing FIGS. 9 and 10 showing a disk die opening limit as at 47 anda disk-guiding shaft as at 56 formed in the main base plate 30 forenhancing axially aligned delivery of the disk(s) 19 into the liddepression 21 for forming two-piece lid assembly 13. FIG. 41 is a firstsequential view showing the upper lid body or disk 19 still attached tothe web 20 as at support cone carrier element 11. This upper lid body ordisk 19 is separated from the support cone carrier element 11 leavingsupport cone carrier element 12 and disk-departed aperture or hole 22,and further directed into the disk-guiding shaft 56 via the compactorhead 18 as limited by the disk die opening limit 47 and disk die opening55 as comparatively depicted in FIGS. 41 and 42.

Referencing FIGS. 43-43B, the reader will see that the disk 19 travelsdown the disk-guiding shaft 56 for insertion in the axially alignedunderlying lid depression 21 of the lower lid body 10 positioned withinthe main base plate 30. The reader will note that the disk-guiding shaft56 comprises a certain shaft length and that the disk 19 is of limited(arcuate) depth lesser in magnitude relative to the shaft length of thedisk-guiding shaft 56. This structural distinction allows certainalternative disk-to-lid insertion methodology whereby a series of disks19 may be positioned within the disk-guiding shaft 56 for sequential andsuccessive insertion into underlying lid depressions 21 of lower lidbodies 10 as sequentially and successively positioned within the mainbase plate 30 as generally depicted in FIGS. 44 through 45A. In thisregard, it is contemplated that a screw-type disk-feeding mechanism 80,comprising a series of disk-feeding screws 63, may preferably operate todeliver or feed the disks 19 into the lid depressions 21.

Threads 69 of the disk-feeding screws 63 preferably operate to drive thedisks 19 into assembly with the lid depression(s) 21. A disk guide screw29 may also be positioned at the disk sip opening 78 to aid in properdisk rotational alignment. The screw extension 79 and thread roots 81that engage outer edges of the disks 19 are further generally depictedand referenced in FIG. 44B. Referencing FIGS. 45 and 45A, the readerwill there further consider a disk punch 50 received within the disk dieopening 55 with vacuum/pressure being indicated at 82 andvacuum/pressure access shafts or channels 44 as well as a lid supportvacuum/press access line 67 formed in the second intermediate compactorplate 14 and the outer plate 15 for enabling vacuum/pressure to directthe rear surface 40 of the lid depression 21 toward the lid support body45 and disk(s) 19 into engagement with the lid depression(s) 21.

The disk-feeding mechanism 80 more particularly functions to (a)retrieve an upper lid body or disk 19 from the disk die opening limit47; (b) temporarily store multiple disks 19 in the disk-guiding shaft56; (c) forward stored disks 19 towards lid depression(s) 21; and (d)drop an individual lower-most disk 19″ to be inserted into liddepression 21. Using vacuum suction 82 for inserting disk 19″ into liddepression 21 allows the temporary storage of multiple disks 19 in thedisk-guiding shaft 56. The disk 19 is punched out and pressed to punchlimit 47 at plane B of die opening 55.

From punch limit 47 to plane B, the disk 19 is engaged by thread-likedisk-feeding mechanism 80 with disk-feeding screws 63 located inimmediate adjacency to disk-guiding shaft 56. FIG. 44A depicts thethread pitch embracing the edge of the disk 19 at the thread root 81 andthe guide screw 29 is embraced by disk sip opening 78 at its thread root81. The disk-feeding mechanism 80 may incorporate differing means forgrabbing disk(s) 19 from the disk die opening limit 47 for furtherallowing temporary storage of multiple disks in the disk-guiding shaft56, after which stored disks 19 may be forwarded towards the liddepression(s) 21 and inserted into lid depressions 21 for forming lidassemblies 13.

Rotation of the screws 63 and 29 is preferably synchronized and engagedas one disk-feeding mechanism 80. At the punch limit 47 plane B threads69 of the disk-feeding mechanism 80 “grab” an upper most disk 19′ fromat least two opposite directions one of which is on disk-guiding screw29 and forwards the upper most disk 19′ towards lid depression 21 one byone. The last or bottom-most disk 19″, at the end of the thread 69 atplane F of the disk-feeding screws 63 and disk-guiding screw 29 of thedisk-feeding mechanism 80, is inserted into aligned lid depression 21preferably by vacuum suction 82 through lid sip hole 68. The bottom partof the disk-guiding screw 29 extends below the last pitch of the thread69 and below plane F screw extension 79 into lid depression 21 therebyguiding the bottom most disk 19′″ all the way into lid depression 21 andpreventing it from circular dislocation.

There may be multiple disks 19 in transition to lid depression 21 in thedisk-feeding mechanism 80. The disk-feeding mechanism 80 couldconceivably accommodate a large number of disks 19, perhaps on the orderof thousands of disks 19, while also accommodating as few as 2-10 disks19. Having multiple disks 19 in the disk-feeding mechanism 80 at thestarting cycle allows disks 19 to be inserted into approaching lower lidbodies or primary lid formations 10, which bodies or formations 10 haveno need to then wait when web 20 moves through the loop 102 and thefirst support cone carrier element 11 aligns with the conicalcountersink 54 of the main base plate 30. In other words, thedisk-feeding mechanism 80 may eliminate dependence on thesynchronization of movements of disk punch 50 and ensuing assembly ofupper lid bodies or disks 19 into lid depression(s) 21 in tandem withother tooling operations.

This alternative arrangement, for example, not only eliminates the needfor compactor shaft 17, but also gives the operator more options interms of placement of disks 19 with a one-to-one ratio with lower lidbodies 10 on the web 20, and in different configurations andarrangements. For example, disks 19 could be separately formed and fedto the disk punch 50 from separate direction or the number of rows ofdisks 19 could follow the same number of rows of lower lid bodies 10.Disks 19 may further be punched out and temporarily stored in thedisk-feeding mechanism 80. When rows of lower lid bodies 10 startaligning with the disk-feeding mechanism 80, disks 19 may besequentially and successively inserted into sequential and successivelid depressions 21 row by row.

The reader will note that to minimize effect of building pressure andvacuum in chamber 26 created between plane C (i.e. the top of thecompactor's head nest 24) and plane D (i.e. the bottom of thedisk-guiding shaft 56 (See FIG. 56)) during the process of rapid backand forth movement of the compactor shaft 17, pressure/vacuum releasechannel 59 continually connects through all plates (shown with hiddenlines in FIG. 55). The reader will further note that the back end of thecompactor's push pin 49 comprises a mechanism with spring 58 to prevent“hard landing” of the compactor head 18 on the lid support body 45 forpreventing damage to upper lid bodies or disks 19 or the lower lidbodies or primary lid formations 10.

The reader will further note that the disk 19 could be inserted into liddepression 21 by vacuum suction through lid support vacuum/pressureaccess line 67 which may be aligned with lid sip hole 68, or bycombination vacuum suction through lid sip hole 68 and by pressure fromcompactor head 18. In this regard, vacuum/pressure access line 67 at lidsupport body 45 may be preferably aligned with lid sip hole 68 and mayserve as vacuum/pressure release from the disk-guiding shaft 56 anddisk-feeding mechanism 80. The disk-guiding shaft 56 may thus serve ascertain disk storage means whereby disks 19 are stored within thedisk-guiding shaft 56. An upper-most disk as at 19′ is positioned insuperior adjacency to stored disks 19 such that a lower-most disk 19′″is insertable into lid depression 21 during the compaction processdescribed hereinabove. This process provides a built-in storage supplyof disks 19 so as to provide flexibility for the system.

Referencing FIGS. 76-79, the reader will there consider a precisionadjustment feature according to the present invention designed toincrease/decrease diameter/size of punched workpiece thermoformed withresilient material exemplified by plastic. Comparing FIGS. 78 and 79,the reader will there see the relaxed diameter of the disk insert 19 asat D2, with an actuated diameter as at D1 defined by the disk-guidingshaft 56. The inherent resiliency of the material construction of theupper lid body or disk 19 provides the manufacturer with a means forprecision adjustments within the diameters of D1 and D2.

Comparatively referencing FIGS. 76 and 77, the reader will note supportcone carrier element 11 in FIG. 76 and support cone carrier element 11′in FIG. 77. The support cone carrier element 11′ is a resilientlydeformed support cone carrier element 11, having been resilientlydeformed via the compactor head 18 as pushed from the normal (default)position by push pin screw 83 thereby further resiliently deforming thearch of disk 19 to form an arch-deformed disk “19D”. The force thatresiliently deforms the disk 19 into arch-deformed disk 19D also deformssupport cone carrier element 11 into support cone carrier element 11′where the horizontal length of the support cone carrier element 11′deformation is referenced at 86.

Fixating screws 84 may preferably operate to secure the push pin screws83 into preferred placement for adjusting the compactor head 18 adistance 85 thereby further resiliently deforming the support conecarrier element 11′ a horizontal support cone carrier elementdeformation distance 86. The support cone carrier element 11 comprises asupport cone carrier element shoulder as at 87 and the direction of sizeexpansion is referenced at 88 once the disk 19 is punched and pushedfrom the disk-guiding shaft 56, the diameter of which equals to D0(default diameter). The internal resistivity or resilient force of thematerial construction of the disk 19D pushes the outer diameter of thedisk in the direction 88 to D2 or its relaxed diameter. The adjustmentsenabled by way of the screws 83 (and 84) and inherent resiliency of thematerial construction thereby allow the provider to adjust diskdimensions while holding punch and die dimensions constant.

It will thus be understood that a method for precision adjustment ofdimensions of parts made from resilient (e.g. plastic) material duringdie cutting is supported by the foregoing. When precision of fittedparts exemplified by the upper lid body or disk 19 is part of theprotocol or practice, adjustments are sometimes necessary to adjust forprecision, and state of the art practices typically require themanufacturer to cut new tool dies and punches. To avoid forming new tooldies and punches, the present invention provides for flexibility in thatthe dimensions (e.g. size or diameter) of the upper lid body or disk 19(as an example) may be adjusted slightly to either side with the samediameter of punch and die by manipulating the structure of the part whenit still on the web 20 and just before the punch drives it into the diethereby providing an effective way of dimensional precision control.

Referencing FIGS. 46-49, the reader will there consider certainmethodology for staggering lower lid body 10 and upper lid body 19pre-assembly arrangements on the web 20. As earlier indicated, the mainbase plate 30 is immovable or stationary. On one side of the main baseplate 30, the web 20 preferably moves in a downward or first directionand on the other side of the main base plate 30 the web 20 preferablymoves in an upward or second direction opposite to the first direction.In the preferred embodiment, the web 20 is a single, continuous web 20reversed in direction by the loop mechanism 102, which flips over theweb 20 such that projected sides of the web 20 with lower lid bodies 10and support cone carrier elements 11 (with disks 19) face one another.The indexation pre-positions the lower lid body or primary lid formation10 to face corresponding lid nest 31 and support cone carrier element 11(with the disk 19) to face corresponding conical countersink 54. Theplates 9/14 and 15/16 are positioned to start synchronized movement toand fro or back and forth relative to main base plate 30.

FIG. 47 depicts alignment lines 27 between the upper lid body or disk 19on support cone carrier element 11, the conical countersink 54 and thedisk punch 50 with conically-shaped locator ring 52, as well asalignment between the lower lid body or primary lid formation 10, lidnest 31 and lid support body 45. The lid nest 31 and conical countersink54 are pre-positioned on the main base plate 30 in such a way that itlocates the upper lid body or disk 19 in axial alignment relative to thelid depression 21 on the lower lid body 10 such that the disk 19 ispreferably in a rotatably closed position when it is inserted into thelid depression 21. Reference numeral 66 shows direction of precisionalignment adjustment of the web 20. FIG. 48 depicts an optionalcompactor spring 28 for aiding directional movement of the compactorshaft 17 and the compactor head 18.

Referencing FIGS. 50-54, the reader will there consider certainprecision alignment features according to the present invention. Thereader will note that the web 20 is aligned and pressed between the mainbase plate 30 and the first and second intermediate compactor plates 14.An air hole needle 53 pocks an air hole in the upper lid body or disk19. The needle 53 is extended and touches a needle-side surface of theupper lid body or disk 19 before the disk punch cutting edge 51 touchesthe upper lid body or disk 19 surface. The air hole is pocked before theupper lid body or disk 19 is punched out. The needle 53 also helps toprevent dislocation of the upper lid body or disk 19 as further depictedin FIG. 54.

Referencing FIG. 52, the reader will there consider that when the upperlid body or disk 19 is punched out and pressed to the disk punch limit47 at point B of die opening 55, it is pre-positioned to be insertedinto lid depression 21. The distance between the bottom surface of theupper lid body or disk 19 and the top surface of the lid depression 21shown as C′-D′ (equaling the compactor head limit 25 when all plates15/16, 14, and 30 are pressed tightly together as generally depicted inFIG. 55 with reference numeral 25 being presented in FIGS. 56 and 57)equals the travel distance of the compactor shaft 17.

Comparatively referencing FIGS. 55 and 58, however, it will be seen thatat distance Y, the compactor push pin 49 is extended out. This distanceY is reserved for “final” push on compactor head 18 to push out lidassembly 13 edge 62 past the web 20 as depicted in FIGS. 22-24 and 24A.This final push is synchronized with plate 15 moving back and pullingbase 60 and lid support body 45 with it as further seen in FIGS. 22-24A.The surface of the disk-guiding shaft 56 is coated or made slightlysmaller than the die opening 55 (See also FIGS. 10), tighteningdisk-to-shaft tolerance from punch limit point B all the way to the endof disk-guiding shaft 56. Additionally, the disk guide 57 (See alsoFIGS. 43A and 43B) and surface of the compactor head 18 conform withcompactor head side surface of the upper lid body or disk 19 to preventcircular dislocation of the upper lid body or disk 19 as generallydepicted in FIGS. 51, 52, and 52A.

FIGS. 50-52A generally illustrate the points through which the upper lidbody or disk 19 travels before insertion into lid depression 21 and arenot meant to depict a “stop point”. When all parts are moving, the upperlid body or disk 19 is punched out with the disk punch 50 through thedie opening 55 to the disk punch limit B and continuously pushed bycompactor head 18 all the way into lid depression 21 from point B topoint D. Once the upper lid body or disk 19 is seated into the liddepression 21, the compactor shaft 17 reverses direction after it pushesout lid assembly 13 as depicted in FIGS. 22-24A. If other means forpushing out lid assembly 13 are utilized, the compactor shaft 17 stopsits forward motion and reverses direction. The described position ofmechanical parts are presented for illustrative purposes primarily anddo not necessarily represent actual positions of various mechanicalcomponents at any given moment.

Referencing FIGS. 53 and 54, the reader will there consider thatprecision alignment of the lower lid body or primary lid formation 10and support cone carrier element 11 (with disk 19) has been completed.The pre-positioned lower lid body 10 on the web 20 is pressed intocountersink shaped lid nest 31 by conically shaped lid support body 45and the support cone carrier element 11 (with disk 19) on the web 20 ispressed into conical countersink 54 of the main base plate 30. Theintermediate compactor plates 14 on both sides of the main base plate 30and the outer plates 15 are in a pre-punch position. The reader willnote that the upper lid body or disk 19 and the lower lid body 10 arenot yet trimmed. The upper lid body or disk 19 is pressed in by the diskpunch 50 against die opening 55.

The conically shaped locator ring 52 presses against back surface of thesupport cone carrier element 11 with springs 58 not fully compressed.The lower lid body 10 is pressed by the lid support body 45 against lidnest 31 with springs 58 not fully compressed. The web 20 is also notfully pressed between the main base plate 30 and the intermediatecompactor plates 14. At this position, alignment of the lower lid body10 and the support cone carrier element 11 (with disk 19) respectivelyeliminates deficiency, if any. The described position of mechanicalparts are presented for illustrative purposes primarily and do notnecessarily represent actual positions of various mechanical componentsat any given moment.

Referencing FIGS. 55-59, the reader will there consider that when theouter plates 15 and intermediate compactor plates 14 are pressedtogether against the main base plate 30 from opposite directions, theweb 20 is immovably pressed between the intermediate compactor plates 14and the stationary main base plate 30. The support cone carrier element11 is immovably pressed between surfaces of the countersink 54 andconical locator ring 52, and the lower lid body 10 is immovably pressedbetween surfaces of lid support body 45 and lid nest 31. The upper lidbody or disk 19 is inserted into lid depression 21 by compactor shaft 17as pushed by push pin 49 and compactor head 18 pressing it through thedisk-guiding shaft 56 all the way into lid depression 21. A punch limittravel distance is depicted at displacement Y in FIG. 58.

Simultaneously, the circular cutting mechanism 70 as generally andcomparatively depicted in FIGS. 57 and 59 trims the lower lid body 10from the web 20. The circular cutting mechanism 70 is an effective wayof trimming thermoformed articles, and specifically circularly shapedarticles exemplified by the illustrated lower lid bodies or primary lidformations 10 and upper lid bodies or disks 19. The circular cuttingmechanism preferably comprises base ring 73 formed with high precisiontolerances. Specifically, the inner ring surface 75 acts as a bearingsurface against the outer surface of circular support dome 74. The knifeblade tip point 71 is secured in the base ring 73 with the possibilityof blade adjustments in different directions.

The knife blade tip point 71 preferably extends just as far as requiredto cut or slice through material thickness (for example, if materialthickness is .015″, the knife blade tip of knife blade 70 extends0.016″-0.020″ from the top surface of the material thickness). Apressure ball 72 keeps pressure against the material thickness at thetime of circular rotation of knife blade tip point 71. The needlebearing 76 helps to keep constant pressure and rotation of the base ring73 at the same time. It will be understood that the outer surface 77 ofthe base ring 73 may be outfitted with a gear or timing pulley forrotation means.

Referencing FIGS. 60-62, the reader will there consider the outer plates15, first and second intermediate compactor plates 14, and the main baseplate 30 after the staggered upper lid bodies or disks 19 have beeninserted into the staggered lower lid bodies 10. The upper lid body ordisk 19 is inserted into the lower lid body or primary lid formation 10thereby forming a trimmed lid assembly 13. The first and secondintermediate compactor plates 14 and the outer plates 15 reversedirection retreating from the stationary main base plate 30, and the web20 disengages from the main base plate 30.

Disk-departed apertures or holes 22 are formed in the web 20 at thesupport cone carrier element(s) 12 where the disks 19 have been removed,and lower lid body-departed apertures or holes 23 have been formed inthe web 20 where lower lid bodies 10 have been removed. The web 20 isthen ready to advance the next row(s) of lower lid bodies 10 and supportcone carrier elements 11 (with disks 19) as generally depicted in FIG.Nos. 63 and 64. The assembled lid assembly 13 is preferably held on thelid support body 45 by vacuum suction through vacuum/pressure accessshafts or channels 44 or by other means. The lid assemblies 13, asassembled, are then ready to be packaged.

Referencing FIGS. 63 and 64, the reader will there consider the web 20as advanced for positioning the next row(s) of lower lid bodies orprimary lid formations 10 and the upper lid bodies or disks 19 atopsupport cone carrier elements 11. In other words, the lower lid bodies10 and the upper lid bodies 19 are indexed into position and the outerplates 15 and the first and second intermediate compactor plates 14 areat respective limit points. The described position of mechanical partspresented in FIGS. 60-64 are presented for illustrative purposesprimarily and do not necessarily represent actual positions of variousmechanical components at any given moment.

Referencing FIGS. 65-67A, the reader will there consider preferredmovements once the lid assemblies 13 have been assembled. The first andsecond intermediate plates 14 move towards the main base plate 30,pressing the web 20 between the first and second intermediate compactorplates 14 and the main base plate 30. The lid stripper elements or steps43 pull the lid assembles 13 from the lid support bodies 45, asparticularly illustrated and referenced in FIGS. 67 and 67A.

The assembled lid assemblies 13 are dropped down to a packaging chutepreferably by way of a mechanical push mechanism or with help ofvacuum/pressure or under direction of its own weight. The reader willnote that just before lid stripper element(s) or step(s) 43 touch thelid perimeter edge 62, the vacuum suction is preferably disengaged torelease the lid assemblies 13. FIG. 66 is a representation of twosectional views in side by side relation and may be comparativelyreferenced with FIGS. 1 and 65, where FIG. 65 is a cross-sectional viewas sectioned from FIG. 66, and FIG. 1 depicts a reduced view of thestructures otherwise depicted in FIG. 66.

It will thus be understood that the pre-positioning of untrimmed lowerlid bodies or primary lid formations 10 and upper lid bodies or disks 19on the web 20 allows the tooling carrying/holding plates 9/14 and 15/16to move in one horizontal or vertical direction back and forth relativeto stationary main base plate 30 as generally depicted in FIGS. 46-67A.The trimming and inserting steps of upper lid bodies or disks 19 intothe lid depressions 21 of the lower lid bodies or primary lid formations10 are completed without tools changing direction as generally depictedin FIGS. 55-59. There is no requirement for temporary storage ortemporary stoppage of moving parts. The functions of the all-in-onestation(s) are completed in process of synchronized linear clappingmovement of tooling holding the plates 14 and 15 (as in FIGS. 46-67A)and plates 9 and 16 (as in FIGS. 1-26) back and forth in relation to thestationary main base plate 30. The moniker “clapper” fairly andaccurately describes the character of the clap-like or clapping platemovement.

The arrangement of plates 9/14 and 15/16, enabling clap-like movementsof opposed tooling, eliminates complicated directional movement changesof trimmed parts to assembly locations and returns and significantlysimplifies synchronization of the different parts of mechanism timingand movements. The arrangement(s) further eliminate additional“over-stroke position” in order to insure there is no tab closure ordisks 19 left in the die opening from prior cycles, since no disks/tabclosures could be left in either the die opening 55 or disk-guidingshaft 56 following an assembly cycle. It should be noted, that thedisk-guiding shaft 56 sidewalls may be preferably coated withTeflon-like coating or, alternatively, dimensioned to be just a bitsmaller than the die opening 55.

These features allow disks 19, after being trimmed by disk punch 50 andpushed thereby to the die opening limit 47 (as depicted in FIGS. 52 and52A), to be continually pushed through disk-guiding shaft 56 by thecompactor head 18 without significant deviation from its originalpositioning. The reader will note that retention of the disk positionwithin the disk-guiding shaft 56 may alternatively be achieved bydifferent means such as making the disk-guiding shaft 56 withrubber-like material or trimming disks 19 using precision adjustingmethod of trimming as discussed hereinabove.

For example, the disk guide 57 prevents circular movement of the disks19 after trimming as further directed to the lid depression 21.Effectively pre-positioning lower lid bodies 10 and disks 19 on the web20 eliminates possibility for lower lid bodies 10 and disks 19 todeviate from pre-positioned state during the assembly process, creatingsimple, efficient and reliable two-piece or composite article assemblymethod allowing to make high speed inline assembly mechanism with any“over-stroke position” being a part of integrated linear movement ofmechanism. The present invention further eliminates “standby positions”as there is no need pick up, hold, or carry the tab closures or disks.All of these eliminations provide certain simplified composite articleassembly methodology enabled by the all-in-one assembly tooling stationsfor trimming and assembling multiple thermoformed workpieces asexemplified by lower lid bodies 10 and upper lid bodies or disks 19.

The reader will further recall that pre-positioned lower lid bodies 10on the web 20 are pressed into countersink shaped lid nest 31 byconically shaped lid support body 45 as generally depicted in FIGS.47-49. The combination of conically shaped walls of the lid support body45 as suspended from the lid support base 46 on the springs 58 allowslid support top surface 33 and the lid support rim top 35 to touchcorresponding surfaces of the lid top rear surface 38 and the lid ringrear surface 36 before the lid top outer surface 39 touches the lid nestceiling 32 and the lid rim outer surface 37 touches the lid nest rimsurface 34 and before the web 20 is securely pressed between the mainbase plate 30 and the intermediate compactor plates 14. The precisionalignment adjustment happens moments before the lower lid bodies and theweb 20 are immovably pressed between plates 30 and 14 and the lower lidbodies 10 are thereafter immovably pressed between correspondingsurfaces of lid support body 45, the lower lid body 10, and the lid nest31 as generally depicted in FIGS. 55-59.

The reader will further recall that the compactor head 18 conforms tothe upper surface of the upper lid body or disk 19 and creates surfaceto surface contact as generally depicted in FIGS. 47, 48, 51, 52, and52A. The upper lid body or disk 19 is preferably formed on top of thefrustum of the support cone carrier element 11 where the base of thesupport cone carrier element 11 is an extension of the (plastic) web 20.This formation helps to speed up indexation and proper insertion andfixating of frustoconically thermoformed support cone carrier element 11into the corresponding conical countersink 54 of the main base plate 30.

The provision of a multiplicity of these types of formations (asgenerally depicted in FIGS. 27-37) on the continuously advancing web 20allows not only increased speed of indexing and insertion ofcorresponding frustoconically thermoformed support cone carrier elements11 into conical countersinks 54 of the main base plate 30, but does sowith high precision. In this regard, the conically shaped locator ring52 suspended on the spring 58 (See FIG. 47) helps properly alignfrustoconically thermoformed support cone carrier elements 11 on the web20 with corresponding conical countersink 54 on the main base plate 30before the web 20 is immovably pressed between the main base plate 30and the intermediate plate 14 (as seen in FIGS. 51-54) therebyself-adjusting parts into alignment for higher precision.

The following descriptions attempt to build upon the concepts originallydisclosed in U.S. patent application Ser. No. 16/661,765 ('765Application) from which these specifications claim a benefit. In thisregard, the methods of assembly described in the '765 Application can befurther applied to an assembly mechanism incorporating assembly toolingwhereby primary tooling station(s) are designed to act as holdingstations for the main bodies and assembling a composite article carriedor conveyed by a continuous web 20 to a multitude of secondary toolingstations. This alternative assembly methodology may thus be referred toas a mechanized assembly conveyor with peripheral assembly toolingstations.

The multitude (two or more) of secondary tooling stations are positionedopposite the primary tooling station(s), and each secondary toolingstation is designed to cooperate with a corresponding primary toolingstation for centering and directing each part or element pre-positionedon an element-carrying web as at 20 towards a corresponding part orelement centered and directed in pre-assembled position at the primarytooling (station) for subsequent punching or die-cutting for detachingthe part or element from the element-carrying web 20 and assembling eachpart or element of the composite article in proper sequential order.

In other words, multiple parts or elements are prepositioned on theelement-carrying web 20 for assembly with corresponding parts orelements in a properly predesignated assembly order. Theelement-carrying web 20 acts as a moving assembly conveyor bringing eachprepositioned and predesignated part or element to a designated toolingstation for subsequent punching or die-cutting from the element-carryingweb 20 and directing the punched or die-cut element into assembledposition at the composite article position within the system inpredetermined sequence.

This methodology allows the manufacturer to assemble or build compositearticles of significant complexity (e.g. a gearboxes or bearingassemblies) with multiple parts and moving engagements. It is furthercontemplated that this alternative method of assembly according to thepresent invention is designed so as to provide a high speed assemblyline whereby parts or elements are made (e.g. by methods ofthermoforming, stamping, etc.) and assembled in a continuous,conveyor-like manner whereby a web as at element-carrying web 20 acts asa conveyor belt thereby eliminating steps of element storage, retrieval,and out-of-line movements during the process of assembling the compositearticle.

The proposed method of composite article assembly may be utilized inmany different fields of application and is simpler, and more effectivethan a robotic assembly line often involving complex, relatively highercost equipment, and a multitude of three-dimensional movements of eachpart element requiring relatively more time to complete assembly.

It is noted that a primary advantage of certain manufacturing sites ofthe world is low labor costs. Composite article assembly is one of themost labor-intensive aspects of assembling composite articles. Theproposed methodology harnesses preexisting or state of the art partformation methods (e.g. thermoforming, stamping, etc,) whereby parts arepre-formed according to such methods and remain on the element-carryingweb 20 acting as a conveyor. Each part is formed and positioned inparticular order upon the element-carrying web 20 so that web-departingelements as punched out or die cut from the web 20 are assembled into acomposite article assembly in a singular linear movement.

Citing thermoforming methods as a primary example, it is noted that thecost of many composite articles made by thermoforming methods istypically calculated by a markup percentage of the raw material cost,and in many cases the raw material costs are the largest portion of theoverall costs of finished articles. While thermoforming methods provideeffective, high speed methods of manufacturing, costly difficultiesarise when thermoformed article elements require assembly into acomposite article. The proposed alternative method described in moredetail hereinafter minimizes costs incurred during the assembly phase ofotherwise thermoformed elemental parts.

Central to the practice of this alternative methodology is theelement-carrying web as at 20 used as an assembly line conveyor. Toolingplates are positioned adjacent the element-carrying web conveyor 20 andcomprise multiple element-nesting cavities. The element-nesting cavitiesare preferably positioned and dimensioned or configured to fit multipleparts thereby allowing the manufacturer to form and assemble multipleparts into one composite article.

The parts or elements, as formed or outfit upon the element-carrying web20, are particularly positioned and sequenced such that the positionsand sequencing operates to align matable parts as they move along theelement-conveying web 20 in pre-loop and post-loop portions of partconveyance. When pre-loop and post-loop matable parts are positionedinto axial alignment, a web-detachable part may be linearly directed ina singular direction into assembled relation with opposing parts to formcomposite articles. This uni-directional movement is a departure fromthe bi-directional movement of opposed tooling as discussed hereinabovein connection with the “clapping” action of opposed tooling portions.

As prefaced above, the element-carrying or element-conveying web 20 andthe loop mechanism(s) 102 are central to the practice of thisalternative methodology. In other words, looping web conveyors are key.Looping webs 20 allow the manufacturer to layer parts without disruptingthe conveyor effect of the web 20. Further, for more complex articlesmultiple loop mechanisms 102 can be incorporated into the design forchanging the relational spatial position of the element-carrying web 20from typical parallel alignments to angled positions in order toposition corresponding parts in proper axial alignment or linearposition for assembly into the composite article. For example, the web20 acting as conveyor can be turned or twisted 90 degrees as at portion115 in FIG. 94 in order to insert or assemble a part from a 90-degreeangle using unidirectional linear movement of punch and part asgenerally depicted in FIG. 98.

The following is an exemplary listing of fields of art or industries inwhich this alternative method of assembly may prove most useful. It iscontemplated, for example, that the packaging industry provides anynumber of composite packaging products comprising articles havingseveral parts as assembled together to form a composite article. Thiscategory further contemplates multilayered composite articles, includingcups, lids, boxes, trays, etc. that requires multilayering. The lidassemblies described hereinabove, for example, are exemplary and maypreferably comprise a series of components that may be assembled underthe uni-directional movement of detached element into assembled relationwith a fixed receiving part conveyed by the web 20.

It is further contemplated that the toy industry provides any number oftoy-type composite articles comprising several simplistic partsassembled together in a safe manner. It is noted that toy partstypically do not require a high level of precision and durability, butusually require safety features with simple designs and low-costmanufacturing requirements. This category contemplates most articlescomprising simple disposable devices comprising several parts and/or lowfrequency use devices.

It is further contemplated that other target industries may include: thefurniture industry generally, and specifically accessories for thefurniture industry such as simple guides, sliders, turn table-likedevices; the medical industry particularly disposable medical devices;the construction industry for spacer devices, washers for fasteners,sliders, etc.; the vehicle industry in terms of particularly simpleaccessories such as cup holders, trays, clamps, other composite plasticparts; the home goods industry embracing simple gearboxes, andbearing-based goods (e.g. the lazy Susan); the defense industry,particularly simple decoys, and disposable devices requiring lightweight and relative durability at low cost; and the sourcing industry.

Other fields of art in which the presently described methodology isparticularly applicable are the aerospace industry and vehiclemanufacturing industry in terms of carbon fiber and carbon graphitematerial construction. These are composite materials made out of layersor base materials such as fiber resin or fiber mesh impregnated withresin which are combined under high heat processes. As elementscomprising such materials traverse through the heat stations, it iscontemplated that a fiber mesh conveyor may operate to move the partsthrough the heat stations and subsequently to assembly stations asotherwise achieved a continuous thermoformable web during thermoformingprocesses.

It is noted that thermoforming, vacuum-forming, and press-formingprocesses are similar in nature and usually comprise the followingattributes: (a) male and female molds or stamps; (b) sheets of plastic,carbon fiber, metal or paper tightly mimicking mold; (c) individualparts separately attached to the web (mesh, paper pulp layer, sheet) oreasily could be on the web after forming is complete; and (d) parts aredetached from the web for next operation or assembly in manyapplications. The presently described methodology keeps formed parts onthe web as long as it practical to utilize such a web (mesh, paper pulplayer, sheet) as conveyor for bringing formed parts through loops,twists, etc. to properly configured assembly station tooling forcomposite element alignment for subsequent assembly with other partsprepositioned on the same web or even made by different process andintersected with the present methodology.

This alternative methodology is contemplated to provide assembly supportfor any device that is built in layers that does not require highprecession and durability and can be provided at relatively low cost,including most disposable or low frequency use devises for differentindustries. In an effort to depict an exemplary composite assembly orarticle of manufacture, FIGS. 80-87 illustrate a generic four-piece“turn table” type composite article as at 300.

The generic, four-piece “turn table” type composite article 300 ispresented as an exemplary composite article and comprises a firstcomposite element as at 310; a second composite element as at 311; athird composite element as at 312; and a fourth composite element as at313. FIG. 80 depicts the generic four-piece “turn table” type compositeassembly or composite article 300 in a fully assembled configuration andis comparatively depicted adjacent FIG. 81 depicting the first throughfourth composite elements 310, 311, 312, and 313 in exploded relationrelative to one another as axially aligned along assembly alignment axis111.

FIGS. 82-84 further comparatively depict the generic four-piece “turntable” type composite article 300 in various views to show in greaterdetail the axial alignment of the elements 310-313 in exploded relationrelative to one another to help the reader understand how the elementsmay be spatially oriented relative to one another in axial alignmentabout assembly alignment axis 111 before full composite assemblyformation into composite article 300. FIGS. 85-87 further comparativelydepict the generic four-piece “turn table” type composite article 300 invarious views to show in greater detail the axial alignment of theelements 310-313 in assembled relation relative to one another to helpthe reader understand how the elements are spatially positioned afterfull composite assembly formation into composite article 300.

FIG. 88 is a schematic drawing depicting the relative position of afirst set of four individual web-carried composite elements movingdownwardly from top-to-bottom showing the first composite element 310;the fourth composite element 313; the third composite element 312; andthe second composite element 311. The composite elements 310-313 are allfacing the same first direction as at arrow 113. The reader will notethe non-sequential ordered arrangement of the elements 310-313.

The first set of four individual web-carried or web-conveyed compositeelements 310-313 are juxtaposed opposite a second set of four individualweb-conveyed composite elements 310-313 moving upwardly fromtop-to-bottom including a second composite element 311, a thirdcomposite element 312, a fourth composite element 313, and a firstcomposite element 310. The second set of four individual web-conveyedcomposite elements 310-313, having looped through the loop mechanism102, all face a second direction as at arrow 114 opposite the firstdirection 113.

The reader will note the axial alignment as at assembly alignment axis111 of the first and second individual composite elements 310 and 311 atupper and lower portions of the figure. The spacing as at 112 betweenthe center axis of the second composite element 311 and the center axisof the third composite element 312 is preferably the same as the spacing112 between the center axis of the third composite element 312 and thecenter axis of the fourth composite element 313 as conveyed by the web20. The spacing 112 between the centers of the second through fourthcomposite elements 311-313 enables the first composite element 310 totravel the same distance between the first, second and third alignmentcavities 321, 322, and 323.

Comparatively referencing FIGS. 89 and 89A, the reader will thereconsider a first sequential schematic drawing of a continuous web 20with web-carried or conveyed composite elements 310-313 innon-sequential order along with the supporting mechanized assemblystation tooling including a loop mechanism 102. The mechanized assemblystation tooling essentially comprises an alignment plate 325 comprisinga series of elemental alignment cavities as otherwise schematicallydepicted at first alignment cavity 321, second alignment cavity 322, andthird alignment cavity 323.

First composite elements 310 are depicted after looping through the loopmechanism 102. A first composite element 310 is positioned into axialalignment as at assembly alignment axis 111 with a second compositeelement 311 at a first alignment cavity 321 of the mechanized assemblystation tooling with alignment plate 325 for forming a second-to-firstcomposite element assembly or basic composite. FIG. 89A is an enlargedfragmentary view as enlarged from FIG. 89 to show in greater detail theaxial alignment of the first and second composite elements 310 and 311at the first alignment cavity 321 prior to removal of the secondcomposite element 311 from the web or conveyor 20.

FIG. 90 is a second sequential schematic drawing of the continuous webconveyor 20 with web-carried individual composite elements 310-313 . Thesecond composite element 311, in axial alignment with the firstcomposite element 310 at the first alignment cavity 321 of themechanized assembly station tooling, is detached from the web conveyor20 and directed toward the first composite element 310 along theassembly alignment axis 111 for second-to-first element assembly therebyforming a web-carried second-first element composite or basic composite.

FIG. 90A shows in greater detail the axial alignment of the first andsecond composite elements 310 and 311 at the first alignment cavity 321with the second composite element 311 departing the web conveyor 20 andbeing directed along the assembly alignment axis 111 toward the firstcomposite element 310 for forming the web-carried second-first elementcomposite or basic composite as at 314. The departing second compositeelement 311 leaves a second element void as at 311′ in the web conveyor20.

FIG. 91 is a third sequential schematic drawing of the continuous webconveyor 20 with web-carried individual composite elements 310-313depicting a third composite element 312 in axial alignment with thesecond-first element composite or basic composite 314 at a secondalignment cavity of the mechanized assembly station tooling withalignment plate 325. The third composite element 312 is detached fromthe web conveyor 20 and directed toward the second-first elementcomposite or basic composite for third element-to-basic compositeassembly thereby forming a web-carried third-second-first elementcomposite or basi-plus composite as at 315.

FIG. 91A shows in greater detail the axial alignment of the thirdcomposite element 312 and the second-first element composite or basiccomposite at a second alignment cavity 322 with the third compositeelement 312 departing the web conveyor 20 and being directed along anassembly alignment axis 111 toward the second-first element composite orbasic for forming the web-carried third-second-first element compositeor basic-plus composite 315. The departing third composite element 312leaves a third element void as at 312′ in the web conveyor 20.

FIG. 92 is a fourth sequential schematic drawing of the continuous webconveyor 20 with web-carried individual composite elements 310-313depicting a fourth composite element 313 in axial alignment with thethird-second-first element composite or basic-plus composite 315 at athird alignment cavity 323 of the mechanized assembly station toolingwith alignment plate 325. The fourth composite element 313 is detachedfrom the web conveyor 20 and directed toward the third-second-firstelement composite or basic-plus composite 315 for fourth compositeelement-to-basic-plus composite assembly thereby forming a web-carriedfourth-third-second-first element composite or complex composite as at316.

FIG. 92A shows in greater detail the axial alignment of the fourthcomposite element 313 and the third-second-first element composite orbasic-plus composite at the third alignment cavity 323 with the fourthcomposite element 313 departing the web conveyor 20 and being directedalong an assembly alignment axis 111 toward the third-second-firstelement composite or basic plus composite 315 for forming theweb-carried fourth-third-second-first element composite or complexcomposite as at 316. The departing fourth composite element 312 leaves afourth element void as at 313′ in the web conveyor 20.

FIG. 93 is a fifth sequential schematic drawing of the continuous webconveyor 20 with web-carried individual composite elements 310-313depicting the fourth-third-second-first element composite or complexcomposite 316 being detached from the web conveyor 20 thereby providingthe generic “turn table” composite article 300 otherwise depicted inFIGS. 80-87. FIG. 93A shows in greater detail the generic “turn table”composite article 300 being departed from the element-carrying webconveyor 20.

FIG. 94 is a sixth sequential schematic drawing of an alternative oroptional continuous web conveyor 20 with web-carried individualcomposite elements 310-313 and supporting mechanized assembly stationtooling with alignment plate 325 with first and second loop mechanismsas at 102. A first fourth-third-second-first element composite orcomplex composite 316 is conveyed along the web conveyor 20 toward thesecond loop mechanism 102 with an assembly alignment axis 111 extendingin a first dimension.

The second fourth-third-second-first element composite or complexcomposite 316 down-web from the first complex composite 316 is conveyedalong the web conveyor 20 away from the second loop mechanism 102 with a90-degree twist or turn at a twist or turn portion 115 in the webconveyor 20 for re-orienting the assembly alignment axis 111 of thesecond fourth-third-second-first element composite in a second dimensionorthogonal to the first dimension for successive composite assembly at afourth alignment cavity as at 324.

It is contemplated that the fourth alignment cavity 324 at down-webassembly station tooling (and successive tooling stations) can be usedto add-on other outside or peripheral features such as a separately madeshaft for insertion into the exemplary generic “turn table” type complexcomposite 316 while still attached to the web conveyor 20. The inherentflexibility of the web conveyor 20 allows the web conveyor 20 totraverse loop mechanisms 102 and twist or turn portions 115 so as tore-align the plane of the web conveyor 20 for further re-orienting theassembly alignment axes 111 and enabling further add-on elementalfeatures directed thereto from differing directions.

FIG. 95 is a perspective view of an exemplary press frame 330 in supportof the mechanized assembly station tooling according to the presentinvention with a die setup therewithin and a continuous web conveyor 20being directed therethrough. The web conveyor 20 loops through adiagrammatic loop mechanism as at 102 with exposed exemplary individualcomposite elements (thermoformed lid assembly components 10 and 11)being shown formed in a first, downwardly directed portion of the webconveyor 20 before entering the loop mechanism 102.

The first, downwardly directed portion of the web conveyor 20 isdirected through a first die portion of the press frame 330 beforeentering the loop mechanism 102. After traversing the loop mechanism102, the web conveyor 20 is redirected upwardly and a second portion ofthe web conveyor 20 is directed through a second die portion of thepress frame 330. Exposed elemental voids (as exemplified byvoid-surrounding support cone carrier elements 12) are shown in thesecond portion of the web conveyor 20 upwardly exiting the press frame330.

FIG. 96 is a side view of the press frame 330 with die setup otherwisedepicted in FIG. 95 with the continuous web conveyor 20 being directedtherethrough and looping through a diagrammatic loop mechanism 102 withexemplary individual composite elements (thermoformed lid assemblycomponents 10 and 11). The exemplary individual composite elements areshown being conveyed by the first portion of the web conveyor 20downwardly toward the loop mechanism 102 as directed through a first dieportion of the press frame 330. The second portion of the web conveyor20 is conveyed upwardly in parallel relation to the first portion afterleaving the loop mechanism 102 and is directed through a second dieportion of the press frame 330.

FIGS. 98 and 98A are sectional views of the press frame 330 with diesetup otherwise depicted in FIG. 96 sectioned to show otherwise hiddencavities of the alignment plate 325 of the die setup within the pressframe 330. Alignment plate 325 as depicted in FIGS. 98 and 98A is athree-cavity station that functions to align an upper lid body and alower lid body. The first alignment cavity as depicted in FIGS. 98 and98A is a lid disk assembly alignment cavity as referenced at 326; thesecond alignment cavity is a disk pre-punch alignment cavity asreferenced at 327; and the third alignment cavity is a lid pre-punchalignment cavity as referenced at 328.

FIG. 97 is a top view of the press frame 330 with die setup otherwisedepicted in FIG. 95 with the continuous web conveyor 20 being directedtherethrough with a first portion of the web conveyor 20 being directedinto the page as at vector 116 through a first die portion of the pressframe 330 and a second portion of the web conveyor 20 in parallelrelation to the first portion being directed out of the page as atvector 117 through a second die portion of the press frame 330. Thereader will note the unidirectional movement depiction of the pressframe assembly 330 as at vector 120. In this alternative methodology,there is no clapping movement or bi-directional movement of opposedplate tooling as discussed hereinabove in connection with other assemblymethodologies.

The reader will further note that certain plates of the mechanizedassembly station tooling exemplified by press frame 330 may preferablycomprise dedicated cavities for assembling differing parts into thefinal composite article exemplified by the composite article 300. Forexample, at some point of assembly, the composite article may stop at analignment cavity (not specifically illustrated) designed to drop-inmetal or plastic balls (made in separate process) in order to providebearings to make the generic “turn table” composite article 300 moreefficient. The cavities may further provide dual functionality, as bothan assembly-alignment cavity and as an outside element receipt site(e.g. a site to receive add on features such as drop-in bearings (madein a separate process).

The web conveyor 20 with thermoformed and/or prepositioned elementscarried thereby is conveyed to successive sites of assembly with theelements arranged in a predetermined order or sequence and is directedthrough a series of loop mechanisms 102 and alignment cavities to placeeach part in position for simplistic linear motion for the assembly ofthe composite article. One of the most important functions of the webconveyor 20 is to convey composite elements within the simplest motionsfor the assembly.

This alternative assembly methodology may involve human interaction,robotic interaction, and different delivery mechanisms with the primarygoal being to align parts or composite elements with a proper order andlocation in the mechanism during composite article construction and todo so in the way such that assembly movements are highly accurate withassembled composite elements being correctly placed within the finallyformed composite article. In other words, the presently describedalternative methodology envisions a thermoforming web that acts as aconveyor with prepositioned parts that traverses through a series loops,turns and intervals bringing each composite element to its properlocation in proper sequential order for full composite assembly with ahigh degree of accuracy and consistency.

Referring back to FIGS. 68-75, the reader will there consider certainalternative methodology for trimming plastic shapes as prefaced above.There are benefits of cutting specifically rounded or circular-shapedparts exemplified by lower lid bodies or primary lid formations 10 andupper lid bodies or disks 19, etc. The alternative method includes amethod of circularly moving a cutting implement or knife 210 through astack 202 of web sheets 203 for avoiding the need to either die-cut orpress-knife through material layers as is currently done in the state ofthe art.

A single tubular shaft as at 200 is depicted having a diametersufficient to accept a stack 204 of cut lid formations or workpieces205. A shaft-receiving plate assembly 201 comprises shaft-receivingapertures 211 outfitted with certain interface means 207 for drivingexternally located threads 206 formed on the exterior of the tubularshaft 200 and extending the length of the tubular shaft as at arrows208. The shaft-receiving plate assembly 201 is positioned in adjacencyto a stack 202 of web sheets 203 such that the successively stackedworkpieces 215 are positioned adjacent the apertures 211.

As the interface means 207 drives the external threads, the tubularshaft 200 rotates at a high rate of speed as at arrows 212 and is thusdirected into the stack 202 of web sheets 203 for cutting through theweb sheets 203 and separating lid formations or workpieces 205 from thesuccessive sheets 203. The end 209 of the tubular shaft 200 is outfittedwith a cutting implement or knife 210 that cuts through the successiveweb sheets 203 as it is directed as at arrow 213. Each of the web sheets203 has a material thickness 221 (e.g. 0.02 inches) generally extendingin a material plane 220. The cutting implement or knife tip 222 extendsa distance from shaft end plane 223 greater in magnitude than thematerial thickness 221 to cut through the material thickness 221.

While the above descriptions contain much specificity, this specificityshould not be construed as limitations on the scope of the invention,but rather as an exemplification of the invention. In certainembodiments, the basic invention may be said to essentially teach ordisclose certain composite article assembly or two-workpiece assemblymethodologies essentially based on the all-in-one assembly toolingstations through which one or more continuous webs 20 may be directed asdescribed in more detail hereinabove. The concepts describedhereinabove, though directed to a two-piece lid assembly method,naturally apply to two-workpiece assemblies whereby a first and secondworkpiece may be assembled to form a two-workpiece ensemble or compositearticle according to the methods and apparatus discussed above.

The essential composite article assembly or two-workpiece assemblymethod according to the present invention may be said to comprise thebasic steps of forming upper lid bodies or disks as at 19 (i.e. a firstworkpiece) and lower lid bodies or primary lid formations as at 10 (i.e.a second workpiece) via a primary body-forming station as exemplified bythermoforming station(s) 100. The upper lid bodies or first workpieces19 and the lower lid bodies or second workpieces 10 are then positionedinto axial alignment along an assembly alignment axis as at 110 withinan all-in-one assembly tooling station as variously exemplified.

Once positioned into axial alignment with one another, the upper lidbodies or first workpieces 19 and the lower lid bodies or secondworkpieces 10 are directed toward one another within the assemblytooling station along the assembly alignment axis 110 so as to close thedistance between the respectively aligned upper lid bodies/firstworkpieces 19 and the lower lid bodies/second workpieces 10. When thedistance between the respectively aligned upper lid bodies/workpieces 19and lower lid bodies/workpieces 10 approaches zero, the upper lid bodies19 engage the lower lid bodies 10 and, due to the size and shapethereof, assemble under the (forced and) directed engagement into oneanother to form two-piece lid assemblies 13.

As earlier described, the steps of (a) directing the upper lid bodies ordisks 19 and the lower lid bodies or primary lid formations 10 towardone another within the assembly tooling station along the assemblyalignment axis 110, and (b) assembling the upper lid bodies or disks 19with the lower lid bodies or primary lid formations 10 along theassembly alignment axis 110 within the all-in-one assembly toolingstation(s) are performed in a single clap-like or clapping movement ofopposed tooling as exemplified by the plate with access opening 9 orintermediate compactor plates 14 (i.e. combination plates 9/14 whenforming multiple workpiece assemblies in side-by-side, staggeredrelation to one another), and the outer plates 15 or the outer pinsupport plates 16 (i.e. combination plates 15/16 when forming multipleworkpiece assemblies in side-by-side, staggered relation to one another)opposite the stationary main base plate 30 within which upper lidbody-to-lower lid body assembly occurs.

It will be recalled that the present invention is believed centered onthe substantially simultaneous, dual-action, web-cut and disk-to-lidassembly step whereby the opposed tooling is directed towards oneanother for directing an upper lid body or disk 19 into engagement witha lower lid body or primary lid formation 10 for forming lid assemblies13. In other words, when the upper lid body or disk 19 is cut from theweb 20 it is directed (e.g. pushed (i.e. not carried)) into assembledrelation with the lower lid body or primary lid formation 10 also beingremoved from the web 20 during one clap-like, to-and-fro or back andforth tooling movement within the all-in-one assembly tooling station(s)according to the present invention.

The step of forming upper lid bodies or disks 19 and lower lid bodies orprimary lid formations 10 via the primary body-forming station (e.g.thermoforming stations 100) comprises or includes the step of formingthe upper lid bodies 19 and the lower lid bodies 10 on at least onecontinuous web 20 via at least one primary body-forming station. Certainalternative methodology according to the present invention involvesforming the upper lid bodies 19 and the lower lid bodies 10 on at leasta pair of, or at least two continuous webs 20 as generally depicted inFIGS. 7 and 8, and directing the pair or at least two continuous webs 20via at least two separate primary body-forming stations after whichstations, the webs 20 continue in a web-to-station flow or direction(i.e. into or toward a singular all-in-one assembly tooling station).

The composite article assembly method according to the present inventionfurther comprises the step of removing a select body formation from theat least one continuous web 20 before directing upper lid bodies 19 andlower lid bodies 10 toward one another within the assembly toolingstation, which select body formation is selected from the groupconsisting of the upper lid bodies 19 and the lower lid bodies 10. Inother words, either the upper lid body 19 or the lower lid body 10 ispreferably separated (e.g. via a select cutting process) from the web 20before it is further directed toward the other body of the two bodies 19or 10 for further assembly into lid assembly 13. The select cuttingprocess may be selected from the group consisting of a die-cuttingprocess or a circular knife-cutting process.

The composite article assembly method may further preferably comprise orinclude the step of forming upper lid bodies 19 and lower lid bodies 10on the least one continuous web 20 via the at least one body-formingstation such that the upper lid bodies 19 and the lower lid bodies 10are formed in spaced and alternating relation to one another asvariously exemplified and illustrated (e.g. See FIGS. 27-37). Thecomposite article assembly methodology according to the presentinvention may further preferably comprise the step of directing the atleast one continuous web 20 through a secondary body-forming station asexemplified by the stations 101 after forming the upper lid bodies 19and lower lid bodies 10 via the primary body-forming station exemplifiedby the thermoforming stations 100. The secondary body-forming station,as exemplified by station 101, functions to form secondary formations asexemplified by sip holes, air vents, or other similar secondaryapertures in select bodies as selected from the group consisting ofupper lid bodies 19 and lower lid bodies 10.

When the production line is built around a single, continuous web 20,the composite article assembly method may further preferably comprisethe step of directing the spaced and alternating upper lid bodies 19 andlower lid bodies 10 through a loop mechanism as exemplified by loopmechanism 102 so as to axially align the upper lid bodies 19 and lowerlid bodies 10 within the singular assembly tooling station for forminglid assemblies 13. Bearing in mind that the all-in-one assembly toolingstations all provide a basis for the described methodology, themethodology may further preferably comprise the step of directing theupper lid bodies 19 and lower lid bodies 10 into a stationary plate asexemplified by the stational main base plate 30 for structurally ormechanically enhancing axial alignment of the upper lid bodies 19 andthe lower lid bodies 10 during the step of assembling the upper lidbodies 19 with the lower lid bodies along the assembly alignment axis110.

Comparatively referencing FIGS. 41-45, it will be recalled that thecomposite article assembly method according to the present invention mayfurther preferably comprise the step of directing at least two or aseries of first select body formations into the stationary plate (e.g.the main base plate 30) before directing a first of the at least twofirst select body formations into assembled relation with a singularsecond select body formation. The first and second select bodyformations may be selected from the group consisting of the upper lidbodies 19 and the lower lid bodies 10.

In other words, as discussed hereinabove, a series of upper lid bodies19 may be directed into the disk-guiding shaft 56 of the main base plate30 before a first of the upper lid bodies or disks 19 (i.e. thelower-most disk 19″) is expelled, directed, or discharged (e.g. via thedisk-feeding mechanism 80) from the disk-guiding shaft 56 intoengagement with an underlying lid depression 21 of a lower lid body 10.It will thus be understood that the disk-guiding shaft 56 of the mainbase plate 30 may temporarily store at least a second of the at leasttwo first select body formations in the stationary plate exemplified bythe main base plate 30.

The step of directing upper lid bodies 19 and lower lid bodies 10 intothe stationary plate exemplified by the main base plate 30 may furtherpreferably comprise the step of directing upper lid bodies 19 and lowerlid bodies 10 into a series of cavities or chambers are exemplified bythe axially aligned conical countersink 54, the disk-guiding shaft 56,and the lid nest 31. Referencing FIGS. 46, 50, 53, 55, 60, 63, and 65,it will be seen that the main base plate 30 may comprise the cavities orchambers exemplified by the axially aligned conical countersink 54, thedisk-guiding shaft 56, and the lid nest 31 arranged or formed inside-by-side relation within the stationary main base plate 30.

Each of these cavities or chambers respectively comprises a selectassembly alignment axis as at 110. The select alignment axes 110 areparallel to one another. The upper lid bodies 19 are assembled withlower lid bodies 10 in side-by-side relation within the stationary mainbase plate 30 in opposite directions defined by or along the selectalignment axes 110. In other words, for example, a first upper lid body19 is directed into engagement with a first lower lid body 10 in a firstdirection and a second upper lid body 19 is directed into engagementwith a second lower lid body 10 in a second direction opposite the firstdirection in side-by-side relation to the first upper lid body 19 andfirst lower lid body 10 as generally depicted in FIGS. 46, 50, 53, 55,60, 63, and 65.

Referencing FIGS. 76-79, the reader will recall that the presentinvention embraces the concept of adjusting tooling features in a mannerthat cooperates with inherent resiliency of materials to provide forbetter assembly characteristics. For example, screws 83 and 84 may befine-tuned for adjusting the compactor shaft 17 and compactor head 18 soas to resiliently deform the upper lid body 19 prior to separation fromthe web 20 and directed transfer through the disk-guiding shaft 56 intoengagement with the underlying lid depression 21 of a lower lid body 10.Accordingly, the present methodology contemplates the step ofresiliently deforming a select body formation before the step ofassembling upper lid bodies 19 with lower lid bodies 10 along theassembly alignment axis 110 within the assembly tooling station, whichselect body formation is selected from the group consisting of the upperlid bodies 19 and the lower lid bodies 10. The step of resilientlydeforming the select body formation functions to adjustably enhanceupper lid body-to-lower lid body assembly.

The composite article assembly methodology according to the presentinvention further contemplates the step of directing force into a selectbody formation via vacuum/pressure application as enabled, for example,via the compactor push pin vacuum/pressure access channel 48,vacuum/pressure access channels 44, pressure/vacuum release channel 59,and lid support vacuum/pressure access line 67. The select bodyformation may be preferably selected from the group consisting of theupper lid bodies 19, the lower lid bodies 10, and the two-piece lidassemblies 13. In this last regard, it will be recalled that force maybe directed into the lid assemblies 13 for re-directing formed lidassemblies 13 toward the packaging station(s) according to the presentinvention. The composite article assembly method according to thepresent invention may further comprise the step of directing compositearticles or lid assemblies into stacked relation as generally depictedthroughout the drawings submitted in support of these specifications.

Referencing FIGS. 80-98A, the reader will there consider an alternativemulti-piece composite article assembly method according to the presentinvention essentially involves the centralized use of a web conveyor asat 20 provided with a series of multiple, axially alignable compositeelements as exemplified by composite elements 310-313. The compositeelements are formed or provided upon a first face of the web conveyor 20facing a first direction as at arrow 113. The (web) conveyor 20 isdirected through a first loop mechanism as at 102 such that the firstface first faces a second direction (as at arrow 114) opposite the firstdirection when exiting the loop mechanism. First and second compositeelements are then axially aligned within mechanized assembly stationtooling along an assembly alignment axis as at 111.

Once the first and second composite elements are axially aligned, thefirst composite element is directed toward the second composite elementwithin the mechanized assembly station tooling along the assemblyalignment axis. The first composite element with the second compositeelement are then assembled along the assembly alignment axis within themechanized assembly station tooling thereby forming a basic composite asat 314. The method may further comprise the step of twisting theconveyor at a twist portion for re-orienting the assembly alignment axisfor successive elemental alignment and assembly as discussedhereinabove.

The steps of directing the first composite element toward the secondcomposite element within the mechanized assembly station tooling alongthe assembly alignment axis and assembling the first composite elementwith the second composite element along the assembly alignment axiswithin the mechanized assembly station tooling are performed byunidirectionally moving the first composite element along the assemblyalignment axis toward the fixed second composite element. This isperformed in distinction to the clapping movement of opposed platetooling as discussed in connection with other alternative methodologies.

It is contemplated the (web) conveyor primarily functions as anelement-conveying mechanism. In certain applications, the carrierconveyor may be preferably exemplified as a web type conveyor with themultiple, axially alignable composite elements being thermoformedtherein before entry into the mechanized assembly station tooling thatoperates to form composite articles. Sets of the multiple, axiallyalignable composite elements are preferably positioned upon the firstface of the conveyor in spaced and alternating relation to one another.

The multi-piece composite article assembly methodology may furthercomprise the step(s) of directing successive composite elements intoassembled relation with the basic composite within the mechanizedassembly station tooling along successive assembly alignment axesthereby forming a complex composite as at 316. The mechanized assemblystation tooling may preferably alignment cavities formed in an alignmentplate of the tooling such that composite elements may be directedtherethrough for enhancing axial alignment of the composite elementswhen assembling the composite elements along the assembly alignment axiswithin the mechanized assembly station tooling.

Referencing FIGS. 68-75A, the present specifications further contemplatecertain workpiece stacking methodology or workpiece cutting/trimmingmethodology for providing a stacked series of lid formations orcomposite articles for ease of packaging. The workpiece stacking orworkpiece trimming methodology according to the present inventioncontemplates the essential steps of stacking a series of web sheets 203atop one another into a web sheet stack as at 202. Each web sheet 203may provide at least one, but preferably a series of workpieces as at215. The web sheet stack 202 may thus preferably comprise at least onestack of web-based lid bodies or workpieces as at 215.

The web sheet stack 202 may be positioned in (inferior) adjacency to ashaft-receiving plate assembly as at 201, which shaft-receiving plateassembly 201 comprises at least one, but preferably a series ofshaft-receiving apertures or bores as at 211. The at least one stack ofweb-based lid bodies or workpieces 215 are preferably positioned inadjacency to the shaft-receiving aperture(s) 211. At least one tubularshaft 200, but preferably a plurality of tubular shafts as at 200 may bedirected through the web sheet stack 202 via the shaft-receivingaperture(s) 211 thereby separating the web-based lid bodies orworkpieces 215 from the series of web sheets 203 and forming a stackedseries of lid formations or workpieces as at 204.

The stacked series of lid formations or workpieces 204 is linearlydirected into the tubular shaft 200 as the tubular shaft 200 is directedthrough the web sheet stack 202. It will be recalled the tubular shaft200 preferably comprises a tubular shaft end as at 209, which tubularshaft end 209 is preferably outfitted with a cutting implement or knifeas at 210. The cutting implement 210 cuts through the web sheet stack202 as the tubular shaft 200 is directed therethrough. The tubular shaft200 preferably comprises external threads as at 206, and the shaftreceiving aperture or bore 211 is preferably outfitted with athread-driving interface as at 207. The thread-driving interface 207 andexternal threads 206 are cooperable for converting rotational motion asat 212 to linearly directed motion 213 for directing the tubular shaft200 linearly through the web sheet stack 202.

Although the composite article formations exemplified by lid assembliesand packaging systems and methods according to the present inventionhave been described by reference to a number of different embodiments,aspects, and features, it is not intended that the novel combinations orassemblies be limited thereby, but that modifications thereof areintended to be included as falling within the broad scope and spirit ofthe foregoing disclosure, the appended drawings, and the followingclaims.

1. A two-piece lid assembly method, the two-piece lid assembly methodcomprising the steps of: axially aligning upper lid bodies and lower lidbodies within mechanized assembly station tooling along an assemblyalignment axis; directing the upper lid bodies and the lower lid bodiestoward one another within the mechanized assembly station tooling alongthe assembly alignment axis; and assembling the upper lid bodies withthe lower lid bodies along the assembly alignment axis within themechanized assembly station tooling thereby forming two-piece lidassemblies.
 2. The two-piece lid assembly method of claim 1 wherein thesteps of: directing the upper lid bodies and the lower lid bodies towardone another within the mechanized assembly station tooling along theassembly alignment axis; and assembling the upper lid bodies with thelower lid bodies along the assembly alignment axis within the mechanizedassembly station tooling are performed in a single clapping movement ofopposed tooling.
 3. The two-piece lid assembly method of claim 2 whereinthe step of axially aligning upper lid bodies and lower lid bodieswithin the mechanized assembly station tooling along an assemblyalignment axis occurs via at least one continuous web.
 4. The two-piecelid assembly method of claim 3 comprising the step of thermoformingupper lid bodies and lower lid bodies in spaced and alternating relationto one another upon the at least one continuous web.
 5. The two-piecelid assembly method of claim 4 comprising the step of directing thespaced and alternating upper lid bodies and lower lid bodies through aloop mechanism for axially aligning the upper lid bodies and lower lidbodies within the mechanized assembly station tooling.
 6. The two-piecelid assembly method of claim 1 comprising the step of directing thelower lid bodies and upper lid bodies into a stationary plate forenhancing axial alignment of the upper lid bodies and lower lid bodiesduring the step of assembling upper lid bodies with lower lid bodiesalong the assembly alignment axis.
 7. The two-piece lid assembly methodof claim 6 comprising the step of directing at least two first selectbody formations into the stationary plate before directing a first ofthe at least two first select body formations into assembled relationwith a singular second select body formation, the first and secondselect body formations being selected from the group consisting of theupper lid bodies and the lower lid bodies.
 8. The two-piece lid assemblymethod of claim 7 comprising the step of temporarily storing at least asecond of the at least two first select body formations in thestationary plate.
 9. The two-piece lid assembly method of claim 1comprising the step of resiliently deforming a select body formationbefore the step of assembling upper lid bodies with lower lid bodiesalong the assembly alignment axis within the mechanized assembly stationtooling, the select body formation being selected from the groupconsisting of the upper lid bodies and the lower lid bodies, the step ofresiliently deforming the select body formation for adjustably enhancingupper lid body to lower lid body assembly.
 10. A multi-piece compositearticle assembly method, the multi-piece composite article assemblymethod comprising the steps of: providing a conveyor with multiple,axially alignable composite elements upon a first face of the conveyor,the first face facing a first direction; directing the conveyor througha first loop mechanism such that the first face faces a second directionopposite the first direction; axially aligning first and secondcomposite elements within mechanized assembly station tooling along anassembly alignment axis; directing the first composite element towardthe second composite element within the mechanized assembly stationtooling along the assembly alignment axis; and assembling the firstcomposite element with the second composite element along the assemblyalignment axis within the mechanized assembly station tooling therebyforming a basic composite.
 11. The multi-piece composite articleassembly method of claim 10 comprising the step of twisting the conveyorfor re-orienting the assembly alignment axis for successive elementalalignment.
 12. The multi-piece composite article assembly method ofclaim 10 the steps of: directing the first composite element toward thesecond composite element within the mechanized assembly station toolingalong the assembly alignment axis; and assembling the first compositeelement with the second composite element along the assembly alignmentaxis within the mechanized assembly station tooling are performed byunidirectionally moving the first composite element along the assemblyalignment axis toward a fixed second composite element.
 13. Themulti-piece composite article assembly method of claim 10 wherein theconveyor is a singular continuous web and the multiple, axiallyalignable composite elements are thermoformed in the continuous web. 14.The multi-piece composite article assembly method of claim 10 whereinsets of the multiple, axially alignable composite elements arepositioned upon the first face of the conveyor in spaced and alternatingrelation to one another.
 15. The multi-piece composite article assemblymethod of claim 10 comprising the step of directing successive compositeelements into assembled relation with the basic composite within themechanized assembly station tooling along successive assembly alignmentaxes for forming a complex composite.
 16. The multi-piece compositearticle assembly method of claim 10 comprising the step of directing thefirst composite element through a first plate-based cavity for enhancingaxial alignment of the first and second composite elements whenassembling the first composite element with the second composite elementalong the assembly alignment axis within the mechanized assembly stationtooling.
 17. A workpiece trimming method, the workpiece trimming methodcomprising the steps of: stacking a series of web sheets atop oneanother into a web sheet stack; positioning the web sheet stack inadjacency to a shaft-receiving plate assembly, the shaft-receiving plateassembly comprising at least one shaft receiving aperture; and directingat least one tubular shaft through the web sheet stack via theshaft-receiving aperture thereby trimming web-based workpieces from theseries of web sheets and forming a stacked series of workpieces.
 18. Theworkpiece trimming method of claim 17 wherein the stacked series ofworkpieces are linearly directed into the tubular shaft as the tubularshaft is directed through the web sheet stack, the tubular shaft forcollecting the stacked series of workpieces.
 19. The workpiece trimmingmethod of claim 17 wherein the tubular shaft comprises external threadsand the shaft-receiving plate assembly is outfitted with athread-driving interface, the external threads being driven via thethread-driving interface for converting rotational motion to linearlydirected motion and directing the tubular shaft through the web sheetstack.